Disposable absorbent article

ABSTRACT

A disposable garment having a side elastomeric material and a waist elastomeric material is disclosed. The disposable garment has a front region, a back region, a crotch region between the front region and the back region. The disposable garment comprises a chassis, a waist elastomeric material, a side elastomeric material, and seams. The chassis has a topsheet, a backsheet joined with the topsheet, and an absorbent core interposed between the topsheet and the backsheet. The chassis has a central panel having a waist edge and side edges, an ear panel having a waist edge, and a waistband panel in the front region and the back region. The ear panel extends laterally outwardly from each side edge of the central panel. The waistband panel extends longitudinally outwardly from the waist edge of the central panel and the waist edge of the ear panel. The waist elastomeric material is joined to and extending continuously along the waistband panels in the front region and the back region so as to form a continuous extensible waistband in the front region and the back region. The side elastomeric material is joined to the ear panel so as to form extensible ears. The side elastomeric material and the waist elastomeric material are separate elements and are disposed so as not to overlap to each other. The seams join each ear panel to a corresponding portion in the ear panel so as to form two leg openings and a waist opening such that the extensible waistbands form a continuous extensible waist feature.

FIELD

The present invention relates to disposable garments. Examples of suchdisposable garments include disposable underwear, disposable diapersincluding pull-on diapers and training pants, and disposable panties formenstrual use.

BACKGROUND

Infants and other incontinent individuals wear disposable garments suchas diapers to receive and contain urine and other body exudes. Absorbentgarments having fixed sides (e.g., training pants or pull-on diapers)have become popular. In order to contain body exudates as well as to fita wide variety of body shapes and sizes, these garments must fit snuglyabout the waist and legs of the wearer without drooping, sagging orsliding down from its position on the torso as well as fitting largerwearers without causing irritation to the skin due to the product beingtoo tight.

Many types of pull-on garments use conventional elastic elements securedin an elastically contractible condition in the waist and leg openings.For example, pull-on garments known as “balloon type” pants arecontracted by elasticized bands in specific zones of the product whilethe remaining material tends to blouse. Examples of such pull-ongarments are disclosed in U.S. Pat. No. 5,171,239 published on Dec. 15,1992, U.S. Pat. No. 4,610,681 published on Sep. 9, 1986. These garmentswill fit a range of waist and leg sizes due to the fact that thecontractive elastic openings will expand to accommodate various sizewearers. Nonetheless, the range of sizes is limited because the elasticelements, which enable this variation in size, have a limited degree ofstretch. The narrow elastic bands used in the waist opening and the legopenings also tend to concentrate the fit forces in a narrow zone of thewearer's body leading to increased incidence of skin marking of thewearer.

Another type of pull-on garment employs waist elastics and sideelastics. Examples of such garments are disclosed in U.S. Pat. No.4,940,464 published on Jul. 10, 1990, U.S. Pat. No. 5,246,433 publishedon Sep. 21, 1993, U.S. Pat. No. 5,591,155 published on Jan. 7, 1997 andEP publication 0 526 868 A1 published on Feb. 10, 1993. Such garmentshave side elastics at both left and right sides of the garments andwaist elastics extending along a part of the waist opening. The sideelastics are disposed extending between the waist opening and the legopenings. The waist elastics extend only a part of the front waist and apart of the back waist between the left and right side elastics. Theside elastics and the waist elastics do not continuously extend.Therefore, the garments do not continuously stretch around the waistopening and available extensibility around the waist opening is limited.Further, because the side elastic comprises a single elastic materialextending from the waist opening to the leg opening, the side elastichas only homogeneous extensibility between the waist opening and the legopening. It does not allow many flexibility in designing a good formfitting garment, e.g., it does not facilitate designs to differentiatethe property of extensibility around the leg opening from extensibilityaround the waist opening.

Other examples of pull-on garments having waist elastics and sideelastics are disclosed in U.S. Pat. No. 5,545,158 published on Aug. 13,1996 and EP publication 0 547 497 A2 published on Jun. 23, 1993. Thegarment disclosed in U.S. Pat. No. 5,545,158 has a pair of elastic sidesegments and elastic waistbands which are joined to the waist border ofthe garment. The side portions of the elastic waistbands are overlappedwith the elastic side segments and do not substantially inhibit theelasticity of the elastic side segments. However, the portion where theelastic side segments and the elastic waistbands are overlapped becomesbulky and redundant and limits the available stretch by the loweststretch material. Further, the resultant stretch forces are additive inthe overlapped region. In addition, the portion where the two elasticmaterials overlap requires higher force to stretch for application ofthe garment to the wearer. The garment disclosed in EP publication 0 547497 A2 has the essentially same structure, therefore the same drawbacksas the garment disclosed in U.S. Pat. No. 5,545,158. EP publication 0547 497 A2 further discloses a garment comprising a triangular shapedside elastic at both left and right sides of the garment which has adecreased end edge adjacent to the waist elastic and which is stilloverlapped with the waist elastic. Due to the geometry of the triangularshaped side elastic, the garment has portions of significantly reducedextensibility at the sides of the garment between the leg openings andthe waist opening, reducing ease of application and increasing pressureat a portion of the side panel potentially reducing the fit range.

Thus, none of the existing art provides all of the advantages andbenefits of the present invention.

SUMMARY

The present invention relates to a disposable garment. The disposablegarment has a front region, a back region, a crotch region between thefront region and the back region. The disposable garment comprises achassis, a waist elastomeric material, a side elastomeric material, andseams. The chassis has a topsheet, a backsheet joined with the topsheet,and an absorbent core interposed between the topsheet and the backsheet.The chassis has a central panel having a waist edge and side edges, anear panel having a waist edge, and a waistband panel in the front regionand the back region. The ear panel extends laterally outwardly from eachside edge of the central panel. The waistband panel extendslongitudinally outwardly from the waist edge of the central panel andthe waist edge of the ear panel. The waist elastomeric material isjoined to and extending continuously along the waistband panels in thefront region and the back region so as to form a continuous extensiblewaistband in the front region and the back region. The side elastomericmaterial is joined to the ear panel so as to form extensible ears. Theside elastomeric material and the waist elastomeric material areseparate elements and are disposed so as not to overlap to each other.The seams join each ear panel to a corresponding portion in the earpanel so as to form two leg openings and a waist opening such that theextensible waistbands form a continuous extensible waist feature.

The present invention further relates to a disposable garment. Thedisposable garment has a front region, a back region and a crotch regionbetween the front region and the back region. The disposable garmentcomprises a chassis, a waist elastomeric material, a side elastomericmaterial, and seams joining parts of the disposable garment in the frontregion to parts of the disposable garment in the back region so as toform a waist opening and leg openings. The garment has a continuous beltzone which is formed by at least the waist elastomeric material and theside elastomeric material. The continuous belt zone is extensible in anextension range up to an extension of at least about 125%. Thecontinuous belt zone has a modulus of extensibility in the extensionrange. The modulus of extensibility at the extension of 125% is notgreater than about 150 g/% extension. The force to obtain the extensionof 125% is not greater than 5,000 g.

The present invention further relates to a disposable garment of thetype of worn about the torso of a wearer. The garment has a frontregion, a back region, a crotch region between the front region and theback region, a waist opening, and leg openings. The garment has a zoneof extensibility comprising a side elastomeric material and a waistelastomeric material. When the garment is applied to a standardmannequin, the skin contact pressure of the side elastomeric materialand the waist elastomeric material pressing on the skin of the standardmannequin is not greater than 0.75 psi.

These and other features, aspects, and advantages of the presentinvention will become evident to those skilled in the art from a readingof the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the inventionwill be better understood from the following description of preferredembodiments which is taken in conjunction with the accompanying drawingsand which like designations are used to designate substantiallyidentical elements, and in which:

FIG. 1 is a perspective view of a preferred embodiment of the disposablepull-on garment of the present invention in a typical in useconfiguration;

FIG. 2 is a simplified plan view of the disposable pull-on garment ofthe present invention in its flat uncontracted, unseamed conditionshowing the various panels of the garment;

FIG. 3 is a simplified plan view of the embodiment shown in FIG. 1 inits flat uncontracted, unseamed condition;

FIG. 4 is a schematically simplified plan view of the embodiment of FIG.3, showing a chassis comprising a topsheet, a backsheet and an absorbentcore therebetween, eliminating the other elements of the pull-ongarment;

FIG. 5 is a cross-sectional view of a preferred embodiment taken alongthe section line 4-4 of FIG. 3;

FIG. 6 is a schematically simplified plan view of the embodiment of FIG.3, showing the disposable pull-on garment having an extensible ear andan extensible waistband;

FIG. 7 is a cross-sectional view of a preferred embodiment taken alongthe section line 6-6 of FIG. 3;

FIG. 8 is a cross-sectional perspective view of an elastic member of apreferred embodiment;

FIG. 9 is a fragmentary enlarged side view of the elastic member shownin FIG. 5;

FIG. 10 is a graph showing the two successive cycles of hysteresiscurves of an elastomeric material, in a preferred embodiment;

FIG. 11 is an enlarged, partially segmented, perspective view of analternative embodiment of the elastomeric material;

FIG. 12 is a cross-sectional view of an alternative embodiment takenalong the section line 6-6 of FIG. 3;

FIG. 13 is a front view of the embodiment shown in FIG. 1;

FIG. 14 is a schematically simplified plan view of an alternativeembodiment of the disposable pull-on garment having an extensible earand an extensible waistband;

FIG. 15 is a schematically simplified plan view of an alternativeembodiment of the disposable pull-on garment having an extensible earand an extensible waistband;

FIG. 16 is a front view of an assembled configuration of the disposablepull-on garment shown in FIG. 15;

FIG. 17 is a front view of an alternative embodiment of an assembledconfiguration of the disposable pull-on garment shown in FIG. 15;

FIG. 18 illustrates force versus extension curve of the continuous beltzone of the disposable pull-on garments of the present invention;

FIG. 19 illustrates modulus of extensibility versus extension curveobtained from the force versus extension curve shown in FIG. 18;

FIG. 20 is a perspective view of the standard mannequin used to measureskin contact pressure;

FIG. 21 is a side view of the standard mannequin shown in FIG. 20;

FIG. 22 is a top view of the standard mannequin shown in FIG. 20.

DETAILED DESCRIPTION

All cited references are incorporated herein by reference in theirentireties. Citation of any reference is not an admission regarding anydetermination as to its availability as prior art to the claimedinvention.

Herein, “pull-on garment” refers to articles of wear which have adefined waist opening and a pair of leg openings and which are pulledonto the body of the wearer by inserting the legs into the leg openingsand pulling the article up over the waist. Herein “disposable” is usedto describe garments which are not intended to be laundered or otherwiserestored or reused as a garment (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner). A“unitary” pull-on garment refers to pull-on garments which are formed ofseparate parts united together to form a coordinated entity, but the earpanels are not separate elements joined to a separate chassis in thatthe ear panels are formed by at least one layer which also forms thecentral panel or chassis of the garment (i.e., the garment does notrequire separately manipulative panels such as a separate chassis andseparate ear panels). The pull-on garment is also preferably “absorbent”to absorb and contain the various exudates discharged from the body. Apreferred embodiment of the pull-on garment of the present invention isthe unitary disposable absorbent pull-on garment, pull-on diaper 20,shown in FIG. 1. Herein, “pull-on diaper” refers to pull-on garmentsgenerally worn by infants and other incontinent individuals to absorband contain urine and feces. It should be understood, however, that thepresent invention is also applicable to other pull-on garments such astraining pants, incontinent briefs, feminine hygiene garments orpanties, and the like. Herein “joined” or “joining” encompassesconfigurations whereby an element is directly secured to the otherelement by affixing the element directly to another element, andconfigurations whereby the element is indirectly secured to the otherelement by affixing the element to intermediate member(s) which in turnare affixed to the other element.

Referring to FIGS. 1, 2, and 3, the pull-on diaper 20 has the frontregion 26, the back region 28 and the crotch region 30 between the frontregion 26 and the back region 28. The pull-on diaper 20 also has twocenterlines; a longitudinal centerline 100, and a transverse centerline110. Herein “longitudinal” refers to a line, axis, or direction in theplane of the pull-on diaper 20 that is generally aligned with (e.g.approximately parallel with) a vertical plane which bisects a standingwearer into left and right halves when the pull-on diaper 20 is worn.Herein “transverse” and “lateral” are interchangeable and refer to aline, axis or direction which lies within the plane of the diaper thatis generally perpendicular to the longitudinal direction (which dividesthe wearer into front and back body halves). The pull-on diaper 20 andcomponent materials thereof also have a body-facing surface which facesthe skin of wearer in use and an outer-facing surface which is theopposite surface to the body-facing surface.

FIG. 2 shows a simplified plan view of the pull-on diaper 20 of FIG. 1in its flat-out, uncontracted state depicting the various panels andtheir positioning with respect to each other. The term “panel” is usedherein to denote an area or element of the pull-on diaper or the belt.(While a panel is typically a distinct area or element, a panel maycoincide (functionally correspond) somewhat with a adjacent panel.) Thepull-on diaper 20 has a crotch region 30 comprising a main panel 2 and apair of leg flap panels 4; a front region 26 comprising a central panel(medial panel) 8, a waistband panel 6, ear panels 10, and seam panels12; and a back region 28 comprising a central panel (medial panel) 9, awaistband panel 7, ear panels 11, and seam panels 13. The crotch region30 is the portion of the pull-on diaper 20 from which the continuousbelt (the other panels) emanates. The absorbent core is generallypositioned within the main panel 2 since exudates are typicallydischarged in this region although the absorbent core will typicallyextend into the medial panels 8 and 9 of the belt. A leg flap panel 4extends generally laterally outwardly from and along each side edge 2Bof the main panel 2. Each leg flap panel 4 generally forms at least aportion of the elastic leg feature. The continuous belt zone (the frontregion 26 and the back region 28) extends generally longitudinallyoutwardly from and along each lateral edge 159 of the crotch region 30(the main panel 2 and the leg flap panel 4). In the front region 26, themedial panel 8 (i.e., central panel) extends generally longitudinallyoutwardly from and along the lateral edge 159 of the crotch region 30.The medial panel 8 has a waist edge 190 and side edges 191. The earpanels 10 each extend generally laterally outwardly from and along theside edge 191 of the medial panel 8 (i.e., central panel). The ear panel10 has a waist edge 161 and a side edge 171. The waistband panel 6extends generally longitudinally outwardly from and along the waist edge190 of the medial panel 8 (i.e., central panel) and the waist edge 161of the ear panel 10. The waistband panel 6 has side edges 175. The seampanels 12 each extend generally laterally outwardly from and along theside edge 171 of the ear panel 10 and the side edge 175 of the waistbandpanel 6. In the back region 28, the medial panel 9 (i.e., central panel)extends generally longitudinally outwardly from and along the otherlateral edge 159 of the crotch region 30. The medial panel 9 has a waistedge 192 and side edges 193. The ear panels 11 each extend generallylaterally outwardly from and along the side edge 193 of the medial panel9 (i.e., central panel). The ear panel 11 has a waist edge 163 and aside edge 173. The waistband panel 7 extends generally longitudinallyoutwardly from and along the waist edge 192 of the medial panel 9 (i.e.,central panel) and the waist edge 163 of the ear panel 11. The waistbandpanel 7 has side edges 177. The seam panels 13 each extend generallylaterally outwardly from and along the side edge 173 of the ear panel 11and the side edge 177 of the waistband panel 7. The front region 26, inaddition to its panels, also has a waist edge 151, leg edges 153, andside edges 154. The back region 28, in addition to its panels, also hasa waist edge 155, leg edges 156, and side edges 157. The crotch region30 has leg edges 158.

The pull-on diaper 20 primarily comprises a chassis 41, a waistelastomeric material (not shown in FIGS. 1, 2, and 3), a sideelastomeric material (not shown in FIGS. 1, 2, and 3), and seams 32. Thepull-on diaper 20 may have tear open tabs 31, whose positioning isassociated with the seams 32 and elasticized leg cuffs 52 includinginner barrier cuffs 54. The side elastomeric material renders at least apart of the ear panel 10 and 11 extensible, thereby forming extensibleear 46 and 48. The waist elastomeric material renders at least a part ofthe waistband panel 6 and 7 extensible, thereby forming continuousextensible waistband 57 and 59. The side elastomeric material and thewaist elastomeric material are separate elements to each other anddisposed so as not to overlap to each other in the longitudinaldirection of the pull-on diaper 20. This allows more independentbehavior of the waist and side elastomeric materials to allow foradjustments in dimension extension, pressure, etc. The extensible ear 46and 48 and continuous extensible waistband 57 and 59 are extensible atleast in the lateral direction. The seam 32 joins the seam panel 12 inthe front region 26 to the seam panel 13 in the back region 28, wherebythe ear panel 10 is joined to the ear panel 11 and whereby one waistopening 36 and two leg openings 34 are formed. In the configurationwhere the ear panel 10 is joined to the ear panel 11, the continuousextensible waistband 57 and 59 forms a continuous extensible waistfeature 60 about the waist opening 36. Further, a continuous belt zone38 extends in the front region 26 and the back region 28.

The chassis 41, referring to FIGS. 3 and 4, the chassis 41 comprises anabsorbent core 25 and a plurality of layers disposed in association withthe absorbent core 25, such as a topsheet 24 and a backsheet 22associated with the topsheet 24. The absorbent core 25 is disposedbetween the topsheet 24 and the backsheet 22. The chassis 41 further mayinclude one or more additional layers disposed associated with theabsorbent core 25. The topsheet 24 has the body-facing surface which ispositioned adjacent to the wearer's body during use. The backsheet 22has the outer-facing surface which is positioned away from the wearer'sbody. Preferably, the backsheet 22 comprises a inner barrier film 68 anda nonwoven outer cover 23. Since the chassis 41 defines the front region26, the back region 28, and crotch region 30, the chassis 41 also hascorresponding regions and panels as previously defined. (For simplicity,these regions and panels are denoted in the drawings by the samereference numerals as the corresponding pull-on diaper regions andpanels as shown in FIG. 2.)

The topsheet 24 and the inner barrier film 68 of the backsheet 22 havelength and width dimensions generally larger than those of the absorbentcore 25. The topsheet 24 and the inner barrier film 68 extend beyond theside edges and end edges of the absorbent core 25 to thereby form theperiphery of the chassis 41. The topsheet 24 longitudinally extendsbetween the waist edge 151 and 155 of the pull-on diaper 20. Thetopsheet 24 has waist end portions 24A and side portions 24B. The waistend portions 24A (i.e., end extended portion 24A) of the topsheet 24extend into a portion of the waistband panel 6 and 7 of the pull-ondiaper 20. The inner barrier film 68 has waist end portions 68A and sideportions 68B. The inner barrier film 68 is a little shorter in thelongitudinal direction than the topsheet 24 and a little wider in thelateral direction than the topsheet 24. The inner barrier film 68 has anonuniform lateral width so as to form a first portion 94 in at least aportion of the crotch region 30 and a second portion 96 in at least aportion of the front or back region 26 and 28. The lateral width of theinner barrier film 68 gradually decreases towards the waist end portions68A such that the second portion 96 has a lateral width dimension lessthan the lateral width dimension of the first portion 94. The innerbarrier film 68 does not preferably extend into the ear panel 10 and 11so as to increase the effective lateral extended length of the ear panel10 and 11 and reduce bulkiness of the ear panel 10 and 11. The innerbarrier film 68 also does not extend into the waistband panel 6 and 7 soas to reduce bulkiness of the waistband panel 6 and 7. In addition,since the inner barrier film 68 does not extend into both the ear panel10 and 11 and the waistband panel 6 and 7, the inner barrier film 68does not inhibit breathability in those areas. While the topsheet 24,the inner barrier film 68, and the absorbent core 25 may be assembled ina variety of well known configurations, exemplary chassis configurationsare described generally in U.S. Pat. No. 3,860,003 entitled“Contractible Side Portions for Disposable Diaper” which issued toKenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No. 5,151,092 entitled“Absorbent Article With Dynamic Elastic Waist Feature Having APredisposed Resilient Flexural Hinge” which issued to Kenneth B. Buellet al., on Sep. 29, 1992.

Preferably, the nonwoven outer cover 23 covers almost all of the area ofthe outermost portion of the pull-on diaper 20. The nonwoven outer cover23 may have generally the same shape as the pull-on diaper 20. Thenonwoven outer cover 23 has waist end portions 23A and side portions23B. The nonwoven outer cover 23 also has a side extended portion 23C inthe front region 26 and a side extended portion 23D in the back region28. The waist end portion 23A (i.e., end extended portion 23A) of thenonwoven outer cover 23 extends into the waistband panel 6 and 7, andthe side extended portion 23C and 23D of the nonwoven outer cover 23extends into the ear panel 10 and 11. Alternatively, the nonwoven outercover 23 of the backsheet 22 may have generally same shape as the innerbarrier film 68 such that the nonwoven outer cover 23 covers only thearea of the inner barrier film 68. Alternatively, the nonwoven outercover 23 may be eliminated, and the inner barrier film 68 may havegenerally the same shape as the pull-on diaper 20 and extend into bothear panel 10 and 11 and waistband panel 6 and 7.

The absorbent core 25 may be any absorbent member which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. The absorbent core 25 may be manufactured in awide variety of sizes and shapes (e.g., rectangular, hourglass,“T”-shaped, asymmetric, etc.) and from a wide variety of liquidabsorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp which is generallyreferred to as airfelt. Examples of other suitable absorbent materialsinclude creped cellulose wadding; meltblown polymers including coform;chemically stiffened, modified or cross-linked cellulosic fibers; tissueincluding tissue wraps and tissue laminates; absorbent foams; absorbentsponges; superabsorbent polymers; absorbent gelling materials; or anyequivalent material or combinations of materials.

The configuration and construction of the absorbent core 25 may vary(e.g., the absorbent core 25 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or maycomprise one or more layers or structures). Further, the size andabsorbent capacity of the absorbent core 25 may also be varied toaccommodate wearers ranging from infants through adults. However, thetotal absorbent capacity of the absorbent core 25 should be compatiblewith the design loading and the intended use of the diaper 20.

The absorbent core 25 in a preferred embodiment has an asymmetric,modified hourglass-shape having ears in the front and back waist regions26 and 28. Other exemplary absorbent structures for use as the absorbentcore 25 that have achieved wide acceptance and commercial success aredescribed in U.S. Pat. No. 4,610,678 entitled “High-Density AbsorbentStructures” issued to Weisman et al. on Sep. 9, 1986; U.S. Pat. No.4,673,402 entitled “Absorbent Articles With Dual-Layered Cores” issuedto Weisman et al. on Jun. 16, 1987; U.S. Pat. No. 4,888,231 entitled“Absorbent Core Having A Dusting Layer” issued to Angstadt on Dec. 19,1989; and U.S. Pat. No. 4,834,735, entitled “High Density AbsorbentMembers Having Lower Density and Lower Basis Weight Acquisition Zones”,issued to Alemany et al. on May 30, 1989.

The chassis 41, as shown in FIG. 5, may further include anacquisition/distribution core 84 of chemically stiffened fiberspositioned over the absorbent core 25, thereby forming a dual coresystem. Preferred dual core systems are disclosed in U.S. Pat. No.5,234,423, entitled “Absorbent Article With Elastic Waist Feature andEnhanced Absorbency” issued to Alemany et al., on Aug. 10, 1993; and inU.S. Pat. No. 5,147,345, entitled “High Efficiency Absorbent ArticlesFor Incontinence Management” issued to Young, LaVon and Taylor on Sep.15, 1992. In a preferred embodiment, the acquisition/distribution core84 comprise chemically treated stiffened cellulosic fiber material,available from Weyerhaeuser Co. (U.S.A.) under the trade designation ofCMC.

More preferably, the chassis 41 may further include anacquisition/distribution layer 82 between the topsheet 24 and theacquisition/distribution core 84 as shown in FIG. 5. Theacquisition/distribution layer 82 is provided to help reduce thetendency for surface wetness of the topsheet 24. Theacquisition/distribution layer 82 preferably comprises carded, resinbonded hiloft nonwoven materials such as, for example, available as CodeNo. FT-6860 from Polymer Group, Inc., North America (Landisiville, N.J.,U.S.A.), which is made of polyethylene terephthalate fibers of 6 dtex,and has a basis weight of about 43 g/m².

The topsheet 24 is preferably compliant, soft feeling, andnon-irritating to the wearer's skin. Further, the topsheet 24 is liquidpervious permitting liquids (e.g., urine) to readily penetrate throughits thickness. A suitable topsheet 24 may be manufactured from a widerange of materials such as woven and nonwoven materials; polymericmaterials such as apertured formed thermoplastic films, aperturedplastic films, and hydroformed thermoplastic films; porous foams;reticulated foams; reticulated thermoplastic films; and thermoplasticscrims. Suitable woven and nonwoven materials can be comprised ofnatural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g.,polymeric fibers such as polyester, polypropylene, or polyethylenefibers) or from a combination of natural and synthetic fibers. Thetopsheet 24 is preferably made of a hydrophobic material to isolate thewearer's skin from liquids which have passed through the topsheet 24 andare contained in the absorbent core 25 (i.e., to prevent rewet). If thetopsheet 24 is made of a hydrophobic material, it is preferable that atleast the upper surface of the topsheet 24 is treated to be hydrophilicso that liquids will transfer through the topsheet more rapidly. Thisdiminishes the likelihood that body exudates will flow off the topsheet24 rather than being drawn through the topsheet 24 and being absorbed bythe absorbent core 25. The topsheet 24 can be rendered hydrophilic bytreating it with a surfactant. Suitable methods for treating thetopsheet 24 with a surfactant include spraying the topsheet 24 materialwith the surfactant and immersing the material into the surfactant. Amore detailed discussion of such a treatment and hydrophilicity iscontained in U.S. Pat. No. 4,988,344 entitled “Absorbent Articles withMultiple Layer Absorbent Layers” issued to Reising, et al on Jan. 29,1991 and U.S. Pat. No. 4,988,345 entitled “Absorbent Articles with RapidAcquiring Absorbent Cores” issued to Reising on Jan. 29, 1991. Thetopsheet 24 may be compatible with ventilation design/process preferablyalong the waistband panel 6 and 7 and other portions on the pull-ondiaper 20.

In preferred embodiments, the topsheet 24 is a nonwoven web that canprovide reduced tendency for surface wetness; and consequentlyfacilitate maintaining urine absorbed by the absorbent core 25 away fromthe user's skin, after wetting. One of the preferred topsheet materialsis a thermobonded carded web which is available as Code No. P-8 fromFiberweb North America, Inc. (Simpsonville, S.C., U.S.A.). Anotherpreferred topsheet material is available as Code No. S-2355 from HavixCo., Japan. This material is a bi-layer composite material, and made oftwo kinds of synthetic surfactant treated bicomponent fibers by usingcarding and air-through technologies. Yet another preferred topsheetmaterial is a thermobonded carded web which is available as Code No.Profleece Style 040018007 from Amoco Fabrics, Inc. (Gronau, Germany).

Another preferred topsheet 24 comprises an apertured formed film.Apertured formed films are preferred for the topsheet 24 because theyare pervious to body exudates and yet non-absorbent and have a reducedtendency to allow liquids to pass back through and rewet the wearer'sskin. Thus, the surface of the formed film which is in contact with thebody remains dry, thereby reducing body soiling and creating a morecomfortable feel for the wearer. Suitable formed films are described inU.S. Pat. No. 3,929,135, entitled “Absorptive Structures Having TaperedCapillaries”, which issued to Thompson on Dec. 30, 1975; U.S. Pat. No.4,324,246 entitled “Disposable Absorbent Article Having A StainResistant Topsheet”, which issued to Mullane, et al. on Apr. 13, 1982;U.S. Pat. No. 4,342,314 entitled “Resilient Plastic Web ExhibitingFiber-Like Properties”, which issued to Radel et al. on Aug. 3, 1982;U.S. Pat. No. 4,463,045 entitled “Macroscopically ExpandedThree-Dimensional Plastic Web Exhibiting Non-Glossy Visible Surface andCloth-Like Tactile Impression”, which issued to Ahr et al. on Jul. 31,1984; and U.S. Pat. No. 5,006,394 “Multilayer Polymeric Film” issued toBaird on Apr. 9, 1991.

The backsheet 22 preferably comprises a inner barrier film 68 and anonwoven outer cover 23. The inner barrier film 68 is preferablyimpervious to liquids (e.g., urine) and is preferably manufactured froma thin plastic film. The inner barrier film 68 has a body-facing surface79 and an outer-facing surface 77. More preferably the plastic filmpermits vapors to escape from the diaper 20. In a preferred embodiment,a microporous polyethylene film is used for the inner barrier film 68. Asuitable microporous polyethylene film is manufactured by Mitsui ToatsuChemicals, Inc., Nagoya, Japan and marketed in the trade as Espoir No.The backsheet 22 is preferably compatible with ventilation and sideseaming design/process. A disposable tape may be further joined to theouter surface of the backsheet.

A suitable plastic film material for the inner barrier film 68 is athermoplastic film having a thickness of from about 0.012 mm (0.5 mil)to about 0.051 mm (2.0 mils), preferably comprising polyethylene orpolypropylene. Preferably, the plastic film has a basis weight of fromabout 5 g/m² to about 35 g/m². However, it should be noted that otherflexible liquid impervious materials may be used. Herein “flexible”refers to materials which are compliant and which will readily conformto the general shape and contours of the wearer's body. The plastic filmmay have moisture vapor transmission rate of between 3,000 and 4,000g/m^(2/24) hr which is measured by a method set froth below.

The nonwoven outer cover 23 is joined with the outer-facing surface ofthe inner barrier film 68 to form a laminate (i.e., the backsheet 22).The nonwoven outer cover 23 is positioned at the outermost portion ofthe pull-on diaper 20 and covers at least a portion of the outermostportion of the diaper 20. The nonwoven outer cover 23 may be joined tothe inner barrier film 68 by any suitable attachment means known in theart. For example, the nonwoven outer cover 23 may be secured to theinner barrier film 68 by a uniform continuous layer of adhesive, apatterned layer of adhesive, or an array of separate lines, spirals, orspots of adhesive. Suitable adhesives include a hotmelt adhesiveobtainable from Nitta Findley Co., Ltd., Osaka, Japan as H-2128, and ahotmelt adhesive obtainable from H.B. Fuller Japan Co., Ltd., Osaka,Japan as JM-6064.

In a preferred embodiment, the nonwoven outer cover 23 is a cardednonwoven web, for example, obtainable from Havix Co., LTD., Gifu, Japanas E-2341. The nonwoven outer cover 23 is made of bi-component fibers ofa polyethylene (PE) and a polyethylene terephthalate (PET). The ratio ofPE/PET is about 40/60. The PE/PET bi-component fiber has the dimensionof 2 decitex×51 mm. Another preferred carded nonwoven web is obtainablefrom Chisso Corp., Osaka, Japan. The nonwoven outer cover 23 is alsomade of bi-component fibers of a polyethylene (PE) and a polyethyleneterephthalate (PET). The ratio of PE/PET is about 30/70.

In another preferred embodiment, the nonwoven web is a spunbondednonwoven web, for example, obtainable from Mitsui PetrochemicalIndustries, Ltd., Tokyo, Japan. The nonwoven web is made of bi-componentfibers consisting of a polyethylene (PE) sheeth and a polypropylene (PP)core. The ratio of PE/PP is about 80/20. The PE/PP bi-component fiberhas the thickness of approximately 2.3 decitex.

The backsheet 22 is preferably positioned adjacent the outer-facingsurface of the absorbent core 25 and is preferably joined thereto by anysuitable attachment means known in the art. For example, the backsheet22 may be secured to the absorbent core 25 by a uniform continuous layerof adhesive, a patterned layer of adhesive, or an array of separatelines, spirals, or spots of adhesive. Adhesives which have been found tobe satisfactory are manufactured by H. B. Fuller Company of St. Paul,Minn. and marketed as HL-1258. An example of a suitable attachment meanscomprising an open pattern network of filaments of adhesive is disclosedin U.S. Pat. No. 4,573,986 entitled “Disposable Waste-ContainmentGarment”, which issued to Minetola et al. on Mar. 4, 1986. Anothersuitable attachment means comprising several lines of adhesive filamentsswirled into a spiral pattern is illustrated by the apparatus andmethods shown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on Oct.7, 1975; U.S. Pat. No. 4,785,996 issued to Ziecker, et al. on Nov. 22,1978; and U.S. Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989.Alternatively, the attachment means may comprise heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment means or combinations of these attachment means as are knownin the art.

In an alternative embodiment, the absorbent core 25 is not joined to thebacksheet 22, and/or the topsheet 24 in order to provide greaterextensibility in the front region 26 and the back region 28.

The elasticized leg cuffs 52 provides improved containment of liquidsand other body exudates. The elasticized leg cuffs 52 may compriseseveral different embodiments for reducing the leakage of body exudatesin the leg regions. (The leg cuff can be and is sometimes also referredto as leg bands, side flaps, barrier cuffs, or elastic cuffs.) U.S. Pat.No. 3,860,003 describes a disposable diaper which provides acontractible leg opening having a side flap and one or more elasticmembers to provide an elasticized leg cuff (gasketing cuff). U.S. Pat.No. 4,909,803 entitled “Disposable Absorbent Article Having ElasticizedFlaps” issued to Aziz et al. on Mar. 20, 1990, describes a disposablediaper having “stand-up” elasticized flaps (barrier cuffs) to improvethe containment of the leg regions. U.S. Pat. No. 4,695,278 entitled“Absorbent Article Having Dual Cuffs” issued to Lawson on Sep. 22, 1987;and U.S. Pat. No. 4,795,454 entitled “Absorbent Article HavingLeakage-Resistant Dual Cuffs” issued to Dragoo on Jan. 3, 1989, describedisposable diapers having dual cuffs including a gasketing cuff and abarrier cuff. U.S. Pat. No. 4,704,115 entitled “Disposable WaistContainment Garment” issued to Buell on Nov. 3, 1987, discloses adisposable diaper or incontinence garment having side-edge-leakage-guardgutters configured to contain free liquids within the garment.

While each elasticized leg cuff 52 may be configured so as to be similarto any of the leg bands, side flaps, barrier cuffs, or elastic cuffsdescribed above, it is preferred that each elasticized leg cuff 52comprises inner barrier cuffs 54 each comprising a barrier flap 56 and aspacing means 58 (as shown in FIG. 5) as described in theabove-referenced U.S. Pat. No. 4,909,803. The inner barrier cuffs 54 mayhave an insert element which is highly impermeable, but preferablybreathable. In a preferred embodiment, the elasticized leg cuff 52additionally comprises an elastic gasketing cuff 62 with one or moreelastic strands 64, positioned outboard of the barrier cuff 54 such asdescribed in the above-referred U.S. Pat. Nos. 4,695,278 and 4,795,454.The elastic strands 64 are generally disposed in the leg flap panel 4and joined to thereto by any means such as hot melt glue under aprestrained condition. The elastic strands 64 may be prestrained, beforebeing joined, up to between 30% and 200%, preferably between 50% and150%. A preferred elastic strands 64 is manufactured by FulflexInternational Company under the designation 9312.

The pull-on diaper 20 has the front extensible ear 46 and the backextensible ear 48. Referring to FIG. 5, the extensible ear 46 and 48preferably comprises a side elastic member 70 having a side elastomericmaterial 124 (shown in FIG. 8), the side extended portion 23C of thenonwoven outer cover 23, and an extended portion 72 of the inner barriercuff 54 (although FIG. 5 depicts only the structures in the front region26, preferably the structures in the back region 28 are the same orsimilar to those in the front region 26). Preferably at least one of thefront and back extensible ears 46 and 48 is elastically extensible in atleast the lateral direction. More preferably, both the front and theback extensible ears 46 and 48 are elastically extensible in at leastthe lateral direction. In an alternative embodiment, the front and backextensible ear 46 and 48 is elastically extensible both in the lateraland longitudinal directions. Herein “extensible” refers to materialsthat are capable of extending in at least one direction to a certaindegree without undue rupture. Herein “elasticity” and “elasticallyextensible” refer to extensible materials that have the ability toreturn to approximately their original dimensions after the force thatextended the material is removed. Herein any material or elementdescribed as “extensible” may also be elastically extensible unlessotherwise provided. The extensible ear 46 and/or 48 provides a morecomfortable and contouring fit by initially conformably fitting thediaper to the wearer and sustaining this fit throughout the time of wearwell past when the diaper has been loaded with exudates since theextensible ear 46 and/or 48 allows the sides of the diaper to expand andcontract.

The extensible ear 46 and 48 preferably has breathability. The moisturevapor transmission rate of the ear panel in conjunction with the overallvapor transmission rate of the rest of the pull-on diaper is importantin reducing the incidence of heat rash and other skin problemsassociated with high heat humidity conditions. In order to reducehumidity and heat humidity within the pull-on diaper, the extensible ear46 and 48 preferably has a weighed average mass vapor transmission rateof at least about 2,000 g/m^(2/24) hr, more preferably at least 4,000g/m^(2/24) hr. Preferably, the entire pull-on diaper has a weighedaverage mass vapor transmission rate of from at least 2,000 g/m^(2/24)hr to about 8,000 g/m^(2/24) hr.

The moisture vapor transmission rate is measured by the method set forthbelow. A known amount of CaCl₂ is put into a flanged cup. A sample isplaced on the top of the cup and held securely by a retaining ring andgasket. The assembly is then weighed and recorded as the initial weight.The assembly is placed in a constant temperature (40° C.) and humidity(75% RH) chamber for 5 hours. The assembly is then removed from thechamber and allowed to equilibrate for at least 30 minutes at thetemperature of the room where the balance is located. The assembly isthen weighed and recorded as the final weight. The mass vaportransmission rate (MVTR) is calculated and expressed in g/m^(2/24) hrusing the following formula.

${MVTR} = \frac{\left( {{{Final}\mspace{14mu}{weight}} - {{Initial}\mspace{14mu}{weight}}} \right) \times 24.0}{{Area}\mspace{14mu}{of}\mspace{14mu}{sample}{\mspace{11mu}\;}{in}\mspace{14mu}{meters} \times 5.0\left( {{time}\mspace{14mu}{in}\mspace{14mu}{chamber}} \right)}$

Referring to FIG. 6 as well as FIG. 3, the extensible ear 46 comprisingthe side elastic member 70 has a higher end edge 46A, a lower end edge46B, an inner side edge 46C, and an outer side edge 46D. The backextensible ear 48 comprising the side elastic material 70 has a higherend edge 48A, a lower end edge 48B, an inner side edge 48C, and an outerside edge 48D. Although a configuration of each element, portion, part,etc. in the front region 26 may be different from that in the backregion 28 (such as configuration of the front extensible ear 46 andconfiguration of the back extensible ear 48, or configuration of thelower end edge 46B and configuration of the lower end edge 48B), thoseelements, portions, parts, etc. which correspond to each other in thefront region 26 and in the back region 28 may be described concurrentlyfor ease of description. In a preferred embodiment, the ear panel 10 and11 is rendered extensible in the entire area of the ear panel 10 and 11to form the extensible ear 46 and 48 by the side elastic material 70. Inthe embodiment shown in FIG. 3, the side elastic material 70 extendsinto a part of the seam panel 12 and 13 so that the front extensible ear46 and the back extensible ear 48 are anchored each other at the seam32, and the side elastic material 70 in the front region 26 and the sideelastic material 70 in the back region 28 are anchored at the seam 32(FIG. 5 also shows the side elastic member 70 which extends into theseam panel 12 and 13, though the seam panel 12 and 13 is not shown inFIG. 5). Alternatively, the ear panel 10 and 11 may be renderedextensible only in a portion of the area in the ear panel 10 and 11. Theextensible ear 46 and 48 is the part of the ear panel 10 and 11 renderedextensible by joining the side elastic member 70 and being subjected tomechanical stretching. In a preferred embodiment, the inner side edge46C and 48C extends generally along the longitudinal center line 100 ofthe pull-on diaper 20. The outer side edge 46D and 48D is non-parallelto the inner side edge 46C and 48C and is non-parallel to thelongitudinal center line 100. The outer side edge 46D and 48D projectslaterally outwardly proximate the lower end edge 46B and 48B. Therefore,the outer side edge 46D and 48D remotes from the inner side edge 46C and48C proximate the lower end edge 46B and 48B. The extensible ear 46 and48 has a lateral width L1 between the inner side edge 46C and 48C andthe outer side edge 46D and 48D proximate the lower end edge 46B and48B, and a lateral width L2 between the inner side edge 46C and 48C andthe outer side edge 46D and 48D proximate the higher end edge 46A and48A. The lateral width between the inner side edge and the outer sideedge is the width between the inner side edge 46C and 48C and the outerside edge 46D and 48D in the lateral direction perpendicular to thelongitudinal center line 100. Therefore, the lateral width between theinner side edge and the outer side is available in the range R where theinner side edge 46C and 48C and the outer side edge 46D and 48Dco-extend in the longitudinal direction. The lateral width L1 is greaterthan the lateral width L2, therefore, the available elastomeric materialquantity in the lateral direction of the extensible ear 46 and 48 isgreater proximate the lower end edge 46B and 48B than proximate thehigher end edge 46A and 48A. Because the outer side edge 46D and 48Dprojects laterally outwardly proximate the lower end edge 46B and 48B,available elastomeric material quantity proximate the lower end edge 46Band 48B is enhanced without reducing available elastomeric materialquantity proximate the higher end edge 46A and 48A. Further, theavailable elastomeric material quantity changes in the direction fromthe higher end edge 46A and 48A toward the lower end edge 46B and 48Bbecause the lateral width of the extensible ear 46 and 48 graduallychanges in that direction. This results in change of forces or forcegradient over the extensible ear allowing for custom fit. The inner sideedge 46C and 48C also may be non-parallel to the longitudinal centerline 100 and project laterally inwardly proximate the lower end edge 46Band 48B such that the lateral width L1 becomes further greater than thelateral width L2. Alternatively, the inner side edge 46C and 48C mayproject a little laterally outwardly proximate the lower end edge 46Band 48B such that the lateral width L1 is still greater than the lateralwidth L2.

The extensible ear 46 and 48 may be formed by unitary elements of thepull-on diaper 20 (i.e., they are not separately manipulative elementssecured to the pull-on diaper 20, but rather are formed from and areextended portions of one or more of the various layers of the pull-ondiaper). In a preferred embodiment, the extensible ear 46 and 48 is aprojected member of the chassis 41. Preferably, the extensible ear 46and 48 comprises at least one unitary element or a continuous sheetmaterial that forms a part of the chassis 41 and continuously extends tothe extensible ear 46 and 48. Alternatively, the extensible ear 46 and48 may be discrete members which do not have any unitary element thatforms a part of the chassis 41. The extensible ear 46 and 48 may beformed by joining the discrete members to the side portions of thechassis 41.

The side elastic member 70 is interposed between the extended portion 72of the inner barrier cuff 54 and the side extended portion 23C and 23Dof the nonwoven outer cover 23 in the region of the extensible ear 46and 48. The side elastic member 70 is operatively joined to at least oneof the extended portion 72 of the inner barrier cuff 54 and the sideextended portion 23C and 23D of the nonwoven outer cover 23. Preferably,the side elastic member 70 is operatively joined to both the extendedportion 72 of the inner barrier cuff 54 and the side extended portion23C and 23D of the nonwoven outer cover 23 while in a substantiallyuntensioned (zero strain) condition.

The side elastic member 70 can be operatively joined to the innerbarrier cuff 54 and the nonwoven outer cover 23, by using either anintermittent bonding configuration or a substantially continuous bondingconfiguration. Herein an “intermittently” bonded laminate web means alaminate web wherein the plies are initially bonded to one another atdiscrete spaced apart points or a laminate web wherein the plies aresubstantially unbonded to one another at discrete spaced apart areas.Conversely, a “substantially continuously” bonded laminate web means alaminate web wherein the plies are initially bonded substantiallycontinuously to one another throughout the areas of interface. Becauseit is preferred that the stretch laminate be bonded over all or asignificant portion of the stretch laminate so that the inelastic webs(i.e., nonwoven webs of the inner barrier cuff 54 and the nonwoven outercover 23) elongate or draw without causing rupture, and the layers ofthe stretch laminates are preferably bonded in a configuration thatmaintains all of the layers of the stretch laminate in relatively closeadherence to one another after the incremental mechanical stretchingoperation, the side elastic member and the other plies of the stretchlaminate are substantially continuously bonded together using anadhesive. In a particularly preferred embodiment, the adhesive selectedis applied in a spiral pattern (such as is shown in U.S. Pat. No.3,911,173 (Sprague, Jr.) and U.S. Pat. No. 4,842,666 (Werenicz)) at abasis weight of about 0.116 g/m². The spirals have a width of about 1.9cm (0.75 in) and either are positioned just next to each other oroverlap slightly (less than 2 mm). The adhesive is preferably anadhesive such as is available from Findley Adhesives under thedesignation H2120. Alternatively, the side elastic member and any othercomponents of the stretch laminates may be intermittently orcontinuously bonded to one another using heat bonding, pressure bonding,ultrasonic bonding, dynamic mechanical bonding, or any other method asis known in the art.

After the side elastic member 70 is operatively joined to the extendedportion 72 of the inner barrier cuff 54 and the side extended portion23C and 23D of the nonwoven outer cover 23, at least a portion of theresultant composite stretch laminate is then subjected to mechanicalstretching sufficient to permanently elongate the non-elastic componentswhich are, for example, the extended portion 72 of the inner barriercuff 54 and the side extended portion 23C and 23D of the nonwoven outercover 23. The composite stretch laminate is then allowed to return toits substantially untensioned condition. The extensible ear 46 and 48 isthus formed into “zero strain” stretch laminates. (Alternatively, theside elastic member 70 could be operatively joined in a tensionedcondition and then subjected to mechanical stretching.) Herein “zerostrain” stretch laminate refers to a laminate comprised of at least twoplies of material which are secured to one another along at least aportion of their coextensive surfaces while in a substantiallyuntensioned (“zero strain”) condition; one of the plies comprising amaterial which is stretchable and elastomeric (i.e., will returnsubstantially to its untensioned dimensions after an applied tensileforce has been released) and a second ply which is elongatable (but notnecessarily elastomeric) so that upon stretching the second ply will be,at least to a degree, permanently elongated so that upon release of theapplied tensile forces, it will not fully return to its originalundeformed configuration. The resulting stretch laminate is therebyrendered elastically extensible, at least up to the point of initialstretching, in the direction of initial mechanical stretching.Particularly preferred methods and apparatus used for making stretchlaminates utilize meshing corrugated rolls or plates to mechanicallystretch the components. Particularly preferred apparatus and methods aredisclosed in U.S. Pat. No. 5,167,897 issued to Weber et al. on Dec. 1,1992; U.S. Pat. No. 5,156,793 issued to Buell et al. on Oct. 20, 1990;U.S. Pat. No. 5,143,679 issued to Weber et al. on Sep. 1, 1992 andEuropean Patent Application No. 98108290.2 titled “METHOD AND APPARATUSFOR ACTIVATING A MOVING WEB” filed on May 7, 1998 (Christoph J. Schmitzet al.).

The side elastic member 70 is preferably joined to, more preferablydirectly secured to the side portions 68B of the inner barrier film 68through an adhesive 76 as shown in FIG. 5. In a preferred embodiment,the side elastic member 70 is joined to the side portions 68B of theinner barrier film 68 at the outer-facing surface 77. In an alternativeembodiment, the side elastic member 70 may be joined to the sideportions 68B of the inner barrier film 68 at the body-facing surface 79.Preferably, the adhesive 76 is applied as an bead. The adhesive 76 maybe applied as a spiral. In a preferred embodiment, the adhesive 76 is aflexible adhesive with an amorphous and crystallizing component. Such apreferred adhesive is supplied by the Findley Adhesive Company under thedesignation #H9224. Alternatively, the side elastic member 70 may bejoined to the side portions 68B of the inner barrier film 68 by anyother bonding means known in the art which comprise heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or combinations ofthese attachment means.

The side elastic member 70 used for extensible ear 46 and 48, referringto FIG. 8, comprises the side elastomeric material 124. The side elasticmaterial 70 may further include one of, preferably both of a firstcoverstock layer 122 and a second coverstock layer 126. Alternatively,the side elastic material 70 may not include any additional layer.

The side elastomeric material 124 has a first surface 150 and a secondsurface 152 opposing the first surface 150, and a first coverstock layer122 which is joined to the first surface 150 of the side elastomericmaterial 124. In a preferred embodiment, the first coverstock layer 122is joined to the first surface 150 of the side elastomeric material 124by an adhesive 160 as shown, for example, in FIG. 9. More preferably,the side elastic member 70 further comprises a second coverstock layer126 which is joined to the second surface 152 of the side elastomericmaterial 124 by an adhesive 164. The side elastomeric material 124provides a good fitness by generating the optimal retention (orsustained) force at the side area of the wearer. Preferably, the sideelastomeric material 124 is extensible in at least one direction,preferably in a direction having a vector component in the lateraldirection to generate a retention (or sustained) force that is optimalto prevent the pull-on diaper 20 from drooping, sagging, or sliding downfrom its position on the torso without causing the red marking on theskin of the wearer.

The side elastomeric material 124 may be formed in a wide variety ofsizes, forms and shapes. In a preferred embodiment, the side elastomericmaterial 124 is in the form of a continuous plane layer. Preferred formsof continuous plane layer include a scrim, a perforated (or aperturesformed) film, an elastomeric woven or nonwoven, and the like. In analternative embodiment, the side elastomeric material 124 is in the formof strands (or strings) which are not connected each other to form acontinuous plane layer. The continuous plane layer may take any shapewhich can be suitably provided in the ear panels. Preferred shapes ofcontinuous plane layer include a quadrilateral including a rectangle anda square, a trapezoid, and the other polygons.

Elastomeric materials which have been found to be especially suitablefor the side elastomeric material 124 are styrenic block copolymer basedscrim materials, perforated (or apertured) elastic films, strands,preferably with a thickness of from about 0.05 mm to about 1.0 mm (0.002inch-0.039 inch). Other suitable elastomeric materials for the sideelastomeric material 124 include “live” synthetic or natural rubber,other synthetic or natural rubber foams, elastomeric films (includingheat shrinkable elastomeric films), elastomeric woven or nonwoven webs,elastomeric composites, or the like.

The extensibility properties of the side elastomeric material 124 suchas the First Cycle Extension Force at 100% Extension (FCEF100%), theFirst Cycle Extension Force at 200% Extension (FCEF200%), the SecondCycle Recovery Force at 50% Extension (SCRF50%) and sustained load at50% after 10-12 hours are important considerations in the performance ofdisposable garments. The side elastomeric material 124 preferably hasextensibility properties within the defined ranges herein. The FCEF100%and the FCEF200% are measures of the overall perceived “stretchiness”during application/removal of disposable garments. These two propertiesalso effect the ability of the applicator to achieve a suitable degreeof application stretch. A side elastomeric material 124 with arelatively high FCEF100% and FCEF200% can cause difficulty in applyingthe disposable garment onto the wearer. On the other hand, a sideelastomeric material 124 with a relatively low FCEF100% and FCEF200% maynot achieve a suitable level of body fitting/conformity. The SCRF50%also closely relates to the body fitting/conformity of disposablegarments for the wearer. A side elastomeric material 124 with arelatively high SCRF50% tends to cause red marking on the skin of thewearer and may be uncomfortable for the wearer during usage. A sideelastomeric material 124 with a relatively low SCRF50% may not provideenough elastic force to keep the diaper in place on the wearer or maynot provide good body fit. The sustained load at 50% evaluates the forcedecay over time. This should be limited or substantial sagging willresult.

The values of FCEF100%, FCEF200% and SCRF50% can be measured by using atensile tester. The tensile tester comprises an upper jaw and a lowerjaw which is located below the upper jaw. The upper jaw is movable andis connected to an extension force measuring means. The lower jaw isfixed on a desk (or floor). A test specimen (i.e., the elastomericmaterial to be measured) which has about 2.54 cm (1.0 inch) in width andabout 12.75 cm (5 inches) in length is prepared and clamped between theupper jaw and the lower jaw so that the effective specimen length (L)(i.e., gauge length) is about 2.54 cm (1.0 inch). The extension force isapplied to the test specimen through the upper jaw. When no extensionforce is applied to the test specimen, the test specimen is in itsuntensioned length. A tensile tester suitable for use herein isavailable from Instron Corporation (100 Royall Street, Canton, Mass.02021, U.S.A.) as Code No. Instron 5564.

FIG. 10 shows one preferred example of the extension and recovery forcecurves for the two cycle hysteresis of the side elastomeric material124. The curve E1 shows the extension force in the first cycle, whilethe curve R1 shows the recovery force in the first cycle. The curve E2(shown in dashed lines) shows the extension force in the second cycle,while the curve R2 shows the recovery force in the second cycle. Theextension and recovery properties are measured as follows.

In the first cycle, the test specimen is subjected to an initialextension force at a crosshead rate of 25.4 cm/min (10 in/min) at about23° C. and held for 30 seconds at 200% extension. The test specimen isthen allowed to relax at the same rate to the untensioned state. Thetest specimen is allowed to remain unconstrained for one minute beforebeing subjected to a second extension force (for the second cycle) atthe same rate and conditions.

In preferred embodiments, the FCEF100% of the side elastomeric material124 is at least about 100 grams/inch. More preferably, the FCEF100% isbetween about 120 to about 220 grams/inch, most preferably between about150 grams/inch and 190 grams/inch. The FCEF200% is preferably betweenabout 160 grams/inch and about 450 grams/inch, more preferably betweenabout 180 grams/inch and about 300 grams/inch, and yet more preferablybetween about 200 grams/inch and about 240 grams/inch. The SCRF50% ofthe side elastomeric material 124 is preferably between about 40grams/inch and about 130 grams/inch, more preferably between about 65grams/inch and about 105 grams/inch, and yet more preferably betweenabout 75 grams/inch and about 95 grams/inch. The sustained load at 50%is preferably between about 40 grams/inch and about 130 grams/inch, morepreferably between about 65 grams/inch and about 105 grams/inch, and yetmore preferably between about 75 grams/inch and about 95 grams/inch.

In the preferred embodiment shown in FIG. 8, the elastomeric scrim 124has a plurality of first strands 125 and a plurality of second strands127. The plurality of first strands 125 intersect the plurality ofsecond strands 127 at nodes 130 at a predetermined angle α, forming anet-like open structure having a plurality of apertures 132. Eachaperture 132 is defined by at least two adjacent first strands and atleast two adjacent second strands, so that the apertures 132 aresubstantially rectangular in shape. Other configurations of theapertures 132, such as parallelograms, squares, or circular arcsegments, can also be provided. Preferably, the first and second strands125 and 127 are substantially straight and substantially parallel to oneanother. Preferably, the first strands 125 intersect the second strands127 at nodes 130 such that the angle α is about 90 degrees. The firstand second strands 125 and 127 are preferably joined or bonded at nodes130. A preferred elastomeric scrim 124 is manufactured by the ConwedPlastics Company under the designation XO2514. This material has about12 elastic strands per inch in the structural direction B (i.e., thefirst strands 125) and about 7 elastic strands per inch in thestructural direction D (i.e., the second strands 127).

In another preferred embodiment shown in FIG. 11, the elastomericmaterial 124 may comprise a porous, macroscopically-expanded,three-dimensional elastomeric web 172. The web 172 has a continuousfirst surface 174 and a discontinuous second surface 176 remote fromfirst surface 174. The elastomeric web 172 preferably comprises a formedfilm having at least two polymeric layers, with at least one of thelayers being an elastomer layer 178 and at least one of the other layersbeing a substantially less elastomeric skin layer 182. The elastomericweb exhibits a multiplicity of primary apertures 184 in the firstsurface 174 of the web 172, the primary apertures 184 being defined inthe plane of the first surface 174 by a continuous network ofinterconnecting members 186. Each interconnecting member 186 exhibits anupwardly concave-shaped cross-section along its length. Theinterconnecting members 186 terminate substantially concurrently withone another to form a secondary aperture 188 in the plane of the secondsurface of the web. The detail of such a structure and the method tomanufacture is disclosed in U.S. patent application Ser. No. 08/816,106,filed Mar. 14, 1997. A preferred porous elastomeric material 124 ismanufactured by the Tredegar Film Products under the designationX-25007. The primary apertures 184 may have any shape. Preferably, theprimary aperture 184 has a shape having a major axis and a minor axisperpendicular to said major axis, such as oval shape, and the major axisis oriented generally orthogonal to applied strain-induced stresses.

In the embodiment shown in FIG. 8, the side elastic member 70 comprisesfirst and second coverstock layers 122 and 126, and side elastomericmaterial 124 disposed in the first and second coverstock layers 122 and126. The first coverstock layer 122 has an inner surface 142 and anouter surface 144. The inner surface 142 of the first coverstock layer122 is the surface that is positioned facing the side elastomericmaterial 124. The second coverstock layer 126 also has an inner surface146 and an outer surface 148. The inner surface 146 of the secondcoverstock layer 126 is the surface that is positioned facing the sideelastomeric material 124. The side elastomeric material 124 also has twoplanar surfaces, first surface 150 and second surface 152, each of whichis substantially parallel with the planes of the first and secondcoverstock layers 122 and 126. The first surface 150 is that planarsurface of the side elastomeric material 124 that is most closelyadjacent with the inner surface 142 of first coverstock layer 122. Thesecond surface 152 is that planar surface of side elastomeric material124 that is most closely adjacent to the inner surface 146 of the secondcoverstock layer 126.

Since the side elastic member 70 will be subjected to mechanicalstretching before and during use, the first and second coverstock layers122 and 126 preferably has a relatively high elongation at breaking, andare more preferably stretchable or elongatable, yet more preferablydrawable (but not necessarily elastomeric), without undue and preferablywithout any, tearing or ripping. Further, the first and secondcoverstock layers 122 and 126 are preferably compliant, soft feeling,and non-irritating to the wearer's skin and give the article the feeland comfort of a cloth garment. Suitable materials for the first andsecond coverstock layers 122 and 126 can be manufactured from a widerange of materials such as plastic films, apertured plastic films, wovenor nonwoven webs of natural fibers (e.g., wood or cotton fibers),synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers), or a combination of naturaland/or synthetic fibers, or coated woven or nonwoven webs.

Preferably, each of the first and second coverstock layers 122 and 126is an identical nonwoven material. An exemplary preferred nonwovenmaterial is manufactured by the FiberWeb Company under the designationDAPP-S tex having a basis weight in the range of 18-35 g/m². Thenonwoven may be consolidated or not consolidated. Preferably, thenonwoven is consolidated for the use of a coverstock layers for anelastomeric scrim. This material has a basis weight in the range of18-35 g/m² before consolidation and a basis weight in the range of about40-70 g/m² after consolidation. As used herein, “basis weight” is theweight of one square meter of planar web material. Alternatively, highlystrainable nonwoven materials may be used. Alternatively, the first andsecond coverstock layers 122 and 126 need not be of identical materials,as long as the desired performance requirements, such as elasticperformance, softness, flexibility, breathability and durability, aremet. As used herein, “consolidated nonwoven material” refers to anonwoven material that has been gathered or necked under mechanicaltension in the structural direction D so that the material can elongatein the structural direction D under low force.

FIG. 9 shows a fragmentary enlarged side view looking into thestructural direction B of the laminate 120 (i.e., the side elasticmember 70). It has been found that when the laminate 120 is bonded orotherwise anchored such that side anchor zones A are created, such alaminate 120 is both highly elastic and substantially free fromdelamination and creep, while providing very good performancecharacteristics in all performance categories with no trade-offs betweenany performance characteristics required. The side anchoring ispreferably performed by side gluing with adhesive beads to anchor theside elastomeric material 124 between the coverstock layers 122 and 126as a part of the lamination process. Alternatively, side anchoring maybe performed by sewing, heat sealing, ultrasound bonding, needlepunching, alternative gluing processes, or by any other means known tothose skilled in the art. Another alternative is to side anchor thelayers of the laminate structure after the lamination of the elastomericand coverstock components has been performed.

Preferably, the laminate 120 may particularly provide very good softfeel for the wearer and for the consumer. This is important becauseconsumers value softness. In conventional laminates, the attempts toeliminate creep have frequently required an unacceptable decrease insoftness, often accompanied by an unacceptable decrease in the abilityto activate. This is because such previous attempts (which have fallenshort of eliminating creep) have focused on the application ofadditional melt blown adhesive, often in an overall coating pattern, inthe attempt to strengthen the bonds. This has generally resulted in anundesirable overall stiffening of the laminate. However, the laminatesof the preferred embodiments provide elimination of creep without theloss of consumer-desired soft feel and without compromise of activationability.

Referring to FIG. 9, a first adhesive 170 is applied to the innersurface 146 of the second coverstock layer 126 in positions thatcorrespond to each of the outer portions 180 of the laminate structure120. The first adhesive 170 may alternatively or additionally be appliedto the inner surface 142 of the first coverstock layer 122. For ease ofillustration, the description and FIGS. refer to application to thesecond coverstock layer 126 only.

This pattern creates side anchor zones A, which substantially eliminatethe delamination and creep associated with previously known laminatesand which allows the laminate 120 to experience higher strains withoutcreeping or delaminating. It has also been found that confining thefirst adhesive 170 to the edge areas 180 of the laminate structure 120avoids impeding the extensibility of the laminate 120 and also avoidstears in the coverstock layers 122 and 126. Preferably, the firstadhesive 170 is applied as a plurality of beads 168, as shown in FIG. 9.Preferably, the first adhesive 170 is a flexible adhesive with anamorphous and crystallizing component. Such a preferred adhesive is madeby the Findley Adhesive Company under the designation H9224.

More preferably, the laminate 120 includes a second adhesive 164. Thesecond adhesive 164 is preferably applied to the second surface 152 ofthe side elastomeric material 124, but could alternatively be applied tothe first surface 150 of the elastomeric material 124. The secondadhesive 164 is preferably applied in a spiral spray pattern 166,thereby forming bond points 167 b that are more discrete than would beformed by a linear spray application. Without being bound by theory, itis believed that most of the second adhesive 164 so sprayed aligns inthe structural direction D. Thus, it has been found that spiral sprayingresults in very good activation properties. As used herein, “activation”refers to the ability to stretch.

It has been found that spraying the layer of second adhesive 164directly onto the second surface 152 of the side elastomeric material124 is more preferable than applying the second adhesive 164 to theopposing (i.e., second) coverstock layer 126. This is because the secondadhesive 164 tends to penetrate through any residual processing agentsor oils that may remain on the surface of the side elastomeric material124. Such residual materials, if left to remain on the side elastomericmaterial 124, may weaken the adhesive bonds and thus the laminatestructure 120 over time. For example, if these residual materials areleft intact, the bonds used to form the laminate 120 may weaken duringthe time interval prior to consumer purchase of the product.

Peel values for the laminate 120 in the spiral adhesive areas aretypically higher when the spirals 166 are applied directly to the sideelastomeric material 124 than to the opposing (i.e., second) coverstocklayer 126. Herein “peel value” refers to the amount of force required toseparate the two layers of coverstock material, 122 and 126, from eachother. Higher peel values typically equate to less chance ofdelamination in use.

A third adhesive 160 may also preferably be applied to the inner surface142 of the first coverstock layer 122. Preferably, the third adhesive160 is an elastomeric adhesive. In a manner similar to that describedwith reference to the second spiral adhesive application 166, the firstadhesive 160 is preferably applied in a spiral spray pattern 162,thereby forming bond points 167 a that are more discrete than would beformed by a linear spray application. Without being bound by theory, itis believed that most of the first adhesive 160 so sprayed aligns in thestructural direction D.

Preferably, second and third adhesives 160 and 164 are the sameelastomeric adhesive. A preferred adhesive for use in the second andthird adhesive spiral sprays 162 and 166 is made by the Findley AdhesiveCompany under the designation H2120. Preferably, the add-on level foreach of the second and third spiral sprays 162 and 166 is about 0.062 toabout 0.186 g/m², more preferably about 0.124 g/m².

Referring to FIG. 1, the pull-on diaper 20 further has the continuousextensible waist feature 60. The continuous extensible waist feature 60improved fit, ease of application and containment. The continuousextensible waist feature 60 is that portion or zone of the pull-ondiaper 20 which is intended to be elastically extensible and contract todynamically fit the wearer's waist. The continuous extensible waistfeature 60 extends along the waistband panel 6 and 7. Preferably, thecontinuous extensible waist feature 60 comprises two separate elements;one continuous extensible waistband 57 positioned in the front region26, and the other continuous extensible waistband 59 positioned in theback region 28, although other pull-on diapers can be constructed with asingle continuous extensible waistband. Referring to FIG. 7 as well, thecontinuous extensible waistband 57 and 59 preferably comprises a waistelastic member 80 having the waist elastomeric material 200 (shown inFIG. 8) and an extended portion of at least one of the plurality oflayers disposed associated with the absorbent core 25, such as thetopsheet 24 and the backsheet 22 (although FIG. 7 depicts only thestructures in the front region 26, preferably the structures in the backregion 28 are the same or similar to those in the front region 26).Preferably the continuous extensible waistband 57 and 59 is elasticallyextensible in at least the lateral direction, more preferably both inthe lateral and longitudinal directions. In a preferred embodiment, thewaistband panel 6 and 7 is rendered extensible at least in the entirelateral length of the waistband panel 6 and 7 to form the continuousextensible waistband 57 and 59 by the waist elastic member 80. In theembodiment shown in FIG. 3, the waist elastic member 80 may extend intothe seam panel 12 and 13 so that the continuous extensible waistband 57and the continuous extensible waistband 59 are anchored each other atthe seam 32, and the waist elastic material 80 in the front region 26and the elastic material 80 in the back region 28 are anchored at theseam 32 (FIG. 7 also shows the waist elastic member 80 which extendsinto the seam panel 12 and 13, though the seam panel 12 and 13 is notshown in FIG. 7). The continuous extensible waistband 57 and 59 formsone continuous extensible waist feature 60 in an assembled configurationof the pull-on diaper 20 as shown in FIG. 1.

The continuous extensible waistband 57 and 59 may be formed by unitaryelements of the pull-on diaper 20 (i.e., they are not separatelymanipulative elements secured to the pull-on diaper 20, but rather areformed from and are extended portions of one or more of the variouslayers of the pull-on diaper). In a preferred embodiment, each of thecontinuous extensible waistband 57 and 59 comprises a projected memberof the chassis 41. Preferably, the continuous extensible waistband 57and 59 comprises at least one unitary element or a continuous sheetmaterial that forms a part of the chassis 41 and continuously extendsinto the continuous extensible waistband 57 and 59. Alternatively, thecontinuous extensible waistband 57 and 59 may be discrete members whichdo not have any unitary element that forms a part of the chassis 41. Thecontinuous extensible waistband 57 and 59 may be formed by joining thediscrete members to the waist portions of the chassis 41.

The continuous extensible waistband 57 and 59 comprises the waistelastic member 80 and an extended portion of at least one of theplurality of layers disposed associated with the absorbent core 25, suchas the topsheet 24 and the backsheet 22. If an additional layer, such asthe inner barrier cuff 54 or an additional liquid absorbing tissuelayer, is added associated with the absorbent core 25, the additionallayer may form a part of the continuous extensible waistband 57 and 59.In a preferred embodiment shown in FIG. 7, the side portion 57B of thecontinuous extensible waistband 57 comprises a lamination of an extendedportion 72 of the inner barrier cuff 54, the end extended portion 23A ofthe nonwoven outer cover 23, and a side part of the waist elastic member80. The central portion 57A of the extensible waistband 57 comprises alamination of the end extended portion 24A of the topsheet 24, the endextended portion 23A of the nonwoven outer cover 23, and a center partof the waist elastic member 80 (although FIG. 7 depicts only thestructures in the front region 26, preferably the structures in the backregion 28 are the same or similar to those in the front region 26).However, in the embodiment, the inner barrier film 68 does not extendinto the continuous extensible waistband 57. Alternatively, the innerbarrier cuff 54, the topsheet 24 and/or the nonwoven outer cover 23 maynot extend into the continuous extensible waistband 57. The extendedportion 72 of the inner barrier cuff 54 also may not extend into thecontinuous extensible waistband 57. If both of the topsheet 24 and thenonwoven outer cover 23 do not extend into the continuous extensiblewaistband 57, the continuous extensible waistband 57 may comprise anextended portion of the inner barrier film 68 and the waist elasticmember 80.

The waist elastic member 80 is superposed inside the innermost surface(body-facing surface) of the pull-on diaper 20. The waist elastic member80 may be operatively joined to the extended portions 72 of the innerbarrier cuffs 54, the end extended portion 23A of the nonwoven outercover 23, and the end extended portion 24A of the topsheet 24. The waistelastic member 80 can be operatively joined thereto, by using either anintermittent bonding configuration or a substantially continuous bondingconfiguration. In a particularly preferred embodiment, the adhesiveselected is applied in a spiral pattern (such as is shown in U.S. Pat.No. 3,911,173 (Sprague, Jr.) and U.S. Pat. No. 4,842,666 (Werenicz)) ata basis weight of about 0.116 g/m². The spirals have a width of about1.9 cm (0.75 in) and either are positioned just next to each other oroverlap slightly (less than 2 mm). The adhesive is preferably anadhesive such as is available from Findley Adhesives under thedesignation H2120. Alternatively, the waist elastic member and any othercomponents of the stretch laminates may be intermittently orcontinuously bonded to one another using heat bonding, pressure bonding,ultrasonic bonding, dynamic mechanical bonding, or any other method asis known in the art.

The entire unstrained length of the waist elastic member 80 ispreferably prestrained in the lateral direction before operativelyjoined to the extended portions 72 of the left and right inner barriercuffs 54, the end extended portion 24A of the topsheet 24, and the endextended portion 23A of the nonwoven outer cover 23. The entireunstained length of the waist elastic member 80 is prestrained in thelateral direction up to at least the original length of the waistbandpanel 6 and 7 of the chassis 41. The entire unstained length of thewaist elastic member 80 may be further prestrained to extend into a partof the seam panel 12 and 13. In the embodiment, the waistband panel 6and 7 of the chassis 41 comprises the extended portions 72 of the leftand right inner barrier cuffs 54, the end extended portion 24A of thetopsheet 24, and the end extended portion 23A of the nonwoven outercover 23. Herein “original length” refers to the length of a singlematerial or a composite material before being rendered elasticallyextensible and before being permanently mechanically stretched. Herein“prestrained entire length” refers to the entire length of an elasticmaterial under a condition where a part of or the entire length of theelastic material is prestrained in the lateral direction. In theembodiment, the original length of the waistband panel 6 and 7 isgenerally the same as the combined length of the extended portions 72 ofthe left and right inner barrier cuffs 54 and the end extended portion24A of the topsheet 24 under an assembled configuration before the waistelastic member 80 is joined thereto. The original length of thewaistband panel 6 and 7 is also generally the same as the length of theend extended portion 23A of the nonwoven outer cover 23 before the waistelastic member 80 is joined thereto. The waist elastic member 80 ispreferably prestrained in range of from 20 to 100% of its unstrained(i.e. untensioned) length. More preferably, the waist elastic member 80may be prestrained in range of from 40 to 80%. After the prestrainedwaist elastic member 80 is joined, the waist elastic member 80 is thenallowed to return to their substantially untensioned condition with theother components, such as the extended portions 72 of the inner barriercuffs 54, the end extended portion 24A of the topsheet 24, and the endextended portion 23A of the nonwoven outer cover 23, joined to the waistelastic member 80. Thus the continuous extensible waistband 57 and 59 isformed that is extensible, from the untensioned length of the waistelastic member 80 at least to the original length of the waistband panel6 and 7 of the chassis 41.

Alternatively, only a part of the waist elastic member 80 may beprestrained before operatively joined to the extended portion of atleast one of the plurality of layers, such that the prestrained entirelength of the waist elastic member 80 in a condition where a part of thewaist elastic member 80 is prestrained is generally the same as theoriginal length of the waistband panel 6 and 7 of the chassis 41.Preferably, only a part of the waist elastic material 80, which extendsalong the lateral width X (shown in FIG. 3) of the absorbent core 25adjacent to the waist elastic material 80, may be prestrained.

Examples of extensible materials are disclosed in U.S. Pat. No.2,075,189 issued to Galligan on Mar. 30, 1937; U.S. Pat. No. 3,025,199issued to Harwood on Mar. 13, 1962; U.S. Pat. Nos. 4,107,364 and4,209,563 issued to Sisson on Aug. 15, 1978 and Jun. 24, 1980,respectively; U.S. Pat. No. 4,834,741 issued to Sabee on May 30, 1989;and U.S. Pat. No. 5,151,092 issued to Buell et al., on Sep. 29, 1992.

The continuous extensible waistband 57 and 59 is formed to beextensible, from the length of the untensioned waist elastic member 80at least up to the original length of the waistband panel 6 and 7 of thechasm 41. However, the waist elastic member 80 is usually joined to theextended portion of a least one of the plurality of layers disposedassociated with the absorbent core 25, such as the topsheet 24 and thebacksheet 22 which are substantially non-elastic. Thereof, the waistelastic member 80 can extend only between the length of the untensionedwaist elastic member 80 and the original length of the waistband panel 6and 7 of the chassis 41, and can not extend beyond the original lengthof the waistband panel 6 and 7 of the chassis 41. This restricts theupper limit of the extension range of the continuous extensiblewaistband 57 and 59 (i.e., continuous extensible waist feature 60), evenif the waist elastomeric material 80 itself is capable of extendingbeyond the original length of the waistband panel 6 and 7 of the chassis41 or the entire length of the prestrained waist elastomeric material80. This restriction in the upper limit of the extension range does notallow enough extensibility for the continuous extensible waistband 57and 59. Therefore, when the pull-on diaper 20 is extended forapplication to the wearer, the pull-on diaper 20 may not provide enoughsize of waist opening or the applicator must apply much high force tothe pull-on diaper 20 to seek extensibility from other extensiblematerials in the pull-on diaper 20 to obtain enough size of waistopening. This may cause difficulty in applying the pull-on diaper to thewearer.

Therefore, the continuous extensible waistband 57 and 59 is renderedelastically extensible to provide greater range of extensibility (i.e.,extension range) beyond the original length of the waistband panel 6 and7 of the chassis 41 or the entire length of the prestrained waistelastic member 80. Namely, after the waist elastic member 80 isoperatively joined under a prestrained (tensioned) condition to theinner barrier cuff 54, the topsheet 24 and the nonwoven outer cover 23and before returning to their substantially untensioned condition, atleast a portion of, preferably the entire of the resultant compositestretch laminate (i.e., continuous extensible waistband 57 and 59) isthen subjected to mechanical stretching sufficient to permanentlyelongate the non-elastic components which are the extended portions 72of the left and right inner barrier cuffs 54, the end extended portion24A of the topsheet 24, the end extended portion 23A of the nonwovenouter cover 23, and the coverstock layers (if any) constituting a partof the waist elastic member 80. The composite stretch laminate is thenallowed to return to its substantially untensioned condition. Therefore,the waist elastic member 80 is extensible from the untensioned lengthbeyond the original length of the waistband panel 6 and 7 of the chassis41 at least up to the permanently elongated length of the non-elasticcomponents. This provides wider extension range for the continuousextensible waistband 57 and 59, thereby providing a benefit of ease ofapplication. Alternatively the waist elastic member 80 may be joined tothe inner barrier cuffs 54, the topsheet 24 and the nonwoven outer cover23 in a substantially untensioned (zero strain) condition so as to forma “zero strain” stretch laminate. Preferred apparatus and methods aredisclosed in U.S. Pat. No. 5,167,897 issued to Weber et al. on Dec. 1,1992; U.S. Pat. No. 5,156,793 issued to Buell et al. on Oct. 20, 1990;U.S. Pat. No. 5,143,679 issued to Weber et al. on Sep. 1, 1992 andEuropean Patent Application No. 98108290.2 titled “METHOD AND APPARATUSFOR ACTIVATING A MOVING WEB” filed on May 7, 1998 (Christoph J. Schmitzet al.).

The waist elastic member 80 comprises the waist elastomeric material 200which can use the same material/structure as the side elastomericmaterial 124. Alternatively, the waist elastomeric material 200 may usematerial/structure different from the side elastomeric material 124. Thewaist elastic member 80 may further include one of, or both of a firstcoverstock layer 202 and a second coverstock layer 204. The structure ofthe waist elastic member 80 may be the same or similar to that of theside elastic member 70. The structure, materials and/or properties ofthe coverstock layers 202 and 204 may be the same or similar to those ofthe coverstock layers 122 and 126, or may be different from those.Further, the method to join the waist elastomeric material 200 to thecoverstock layers 202 and 204 may be the same or similar to the methodof those described for the ear panel member 70 above, or may bedifferent from those. In a preferred embodiment, the waist elasticmember 80 comprises the waist elastomeric material 200 and one layer ofthe coverstock layer 202 or 204. In such a case, the waist elastomericmaterial 200 is disposed facing the inner barrier cuffs 54 and thetopsheet 27, and the coverstock layer 202 or 204 is disposed so as toface and contact the wearer's body such that the wearer's skin is notdirectly pressed by the waist elastomeric material 200 thereby reducingthe incidence of red marking on the skin.

FIG. 12 shows another preferred embodiment of the continuous extensiblewaistband 57 and 59. In this embodiment, the waist elastic member 80 issuperposed inside the nonwoven outer cover 23. Preferably, in the sideportions 57B of the continuous extensible waistband 57, the waistelastic member 80 is interposed between the extended portions 72 of theinner barrier cuffs 54 and the end extended portion 23A of the nonwovenouter cover 23. In the central portion 57A, the waist elastic member 80is interposed between the end extended portion 24A of the topsheet 24and the end extended portion 23A of the nonwoven outer cover 23. Thewaist elastic member 80 may be operatively joined to the extendedportions 72 of the inner barrier cuffs 54, the end extended portion 23Aof the nonwoven outer cover 23, and the end extended portion 24A of thetopsheet 24. In one embodiment, the waist elastic member 80 may comprisethe waist elastomeric material 200 and one layer of the coverstock layer202 or 204. In one case, the waist elastomeric material 200 is disposedfacing the inner barrier cuffs 54 and the topsheet 27, and thecoverstock layer 202 or 204 is disposed facing the nonwoven outer cover23. This disposition of the coverstock layer tends to inhibit the waistelastomeric material 200 is seen through from the outside because onelayer (coverstock layer) is added to interpose between the waistelastomeric material 200 and the nonwoven outer cover 23. In anothercase, the waist elastomeric material 200 is disposed facing the nonwovenouter cover 23, and the coverstock layer 202 or 204 is disposed facingthe inner barrier cuffs 54 and the topsheet 27. This disposition of thecoverstock layer tends to reduce the incidence of red marking on theskin because one layer (coverstock layer) is added to interpose betweenthe waist elastomeric material 200 and the skin of the wearer. In bothcases, because one of the coverstock layers is eliminated (compared withtwo layers of the coverstock layers), bulkiness in the continuousextensible waistband 57 reduces. Further, breathability at thecontinuous extensible waistband 57 enhances because of less materialtherein. In addition, the continuous extensible waistband 57 becomes tohave more available extensibility. The continuous extensible waistband57 is formed by the waist elastic member 80 comprising the waistelastomeric material 200 which is prestrained and then returned to theoriginal untensioned condition in a preferred embodiment. When the waistelastomeric material 200 returns to its original untensioned condition,the other components joined to the waist elastomeric material 200 tendsto inhibit the waist elastomeric material 200 to return its originaluntensioned length. Therefore, the waist elastomeric material 200 cannot utilize the whole extensibility. However, in the embodimentdescribed above, since bulkiness in the continuous extensible waistband57 reduces, the waist elastomeric material 200 can return as close asits original untensioned length. Therefore, the waist elastomericmaterial 200 becomes to have more available extensibility.

Alternatively, the waist elastic member 80 may comprise one layer of thewaist elastomeric material 200 without any coverstock layers. In theside portions 57B of the extensible waistband 57, the waist elastomericmaterial 200 is interposed and joined directly between the extendedportions 72 of the inner barrier cuffs 72 and the end extended portion23A of the nonwoven outer cover 23. In the central portion 57A, thewaist elastomeric material 200 is interposed and joined directly betweenthe end extended portion 24A of the topsheet 24 and the nonwoven outercover 23. This structure is also useful to reduce bulkiness, to enhancebreathability, and to have more available extensibility, in theextensible waistband 57.

The side elastic member 70 and the waist elastic member 80 consist ofseparate elements and both members 70 and 80 are preferably disposed notto overlap to each other in the longitudinal direction. However, bothmembers 70 and 80 are preferably disposed without a substantial gapinbetween such that the members 70 and 80 form a composite elastomericnetwork in the extensible ears 46 and 48. Herein “composite elastomericnetwork” refers to a zone or area where two or more separate elastomericmaterials substantially continue with no gap between the elastomericmaterials or with a predetermined interval, thereby exhibiting abehavior of extensibility like a single elastomeric material.Preferably, both members 70 and 80 are disposed with no gap. Therefore,it is perceived that the extensible ear 46 and 48 and the side portion57B and 59B of the continuous extensible waistband 57 and 59 comprise acontinuous single elastomeric material between the waist opening 36 andthe leg openings in an assembled configuration of the pull-on diaper 20.The side elastic member 70 and the waist elastic member 80 consist ofseparate elements, therefore the side elastomeric material 124 and thewaist elastomeric material 200 also consist of separate elements. Theseparated structure allows the design of the side elastomeric material124 and the waist elastomeric material 200 using different materials ineach components, so this allows different properties of extensibilitysuch as force versus extension curve for different parts of the pull-ondiaper 20. The separated structure also allows use of the sideelastomeric material 124 and the waist elastomeric material 200 indifferent conditions, such as in a prestrained (tensioned) condition oruntensioned condition. This allows differentiation of the force requiredto extend different parts of the pull-on diaper 20 up to the same lengthor equalize force required to extend different parts up to the differentlength, thereby adjusting the pressure applied to the skin of thewearer. For example, the pull-on diaper 20 may have a waist elastomericmaterial 200 provided with high extensibility at low force such that thecontinuous extensible waist feature 60 is extended easily by low forceapplied by the applicator for ease of application of the pull-on diaper20 while the pull-on diaper 20 may have a side elastomeric material 124generating force required for sustained fit at the extensible ear 46 and48, but the force may not give red marking to the skin. In oneembodiment, the continuous extensible waist feature 60 comprising thewaist elastomeric material 200 is designed to have extensibility of atleast 100% while the extensible ear 46 and 48 comprising the sideelastomeric material 124 is designed to have force between 40 g/inch and130 g/inch when the extensible ear 46 and 48 is extended up to 50% (moreconcretely, at SCRF50%).

Both the side elastic member 70 and the waist elastic member 80 aredisposed not to overlap to each other in the longitudinal direction,therefore, the side elastomeric material 124 and the waist elastomericmaterial 200 also do not overlap. Because the side elastic member 70 andthe waist elastic member 80 are not structurally overlapped, each member70 and 80 comprises a single material of extensibility, therefore it hassubstantially homogeneous property of extensibility. This allows theapplicator to extend the pull-on diaper 20 smoothly without feeling thechange of force applied during extending for application of the pull-ondiaper.

The seams 32 each joins the seam panels 12 and 13, thereby joining thecorresponding portions of the extensible ears 46 and 48, and therebyforming two leg openings 34 and one waist opening 36. The front and backextensible ears 46 and 48 are seamed, preferably, along the outer sideedges 46D and 48D, in an overlapped manner to make an overlapped seamstructure. Alternatively, the front and back extensible ears 46 and 48can be seamed in a butt seam manner (not shown in FIGS.). The bonding ofthe seams 32 can be performed by any suitable means known in the artappropriate for the specific materials employed in the front and backextensible ears 46 and 48. Thus, sonic sealing, heat sealing, pressurebonding, adhesive or cohesive bonding, sewing, autogeneous bonding, andthe like may be appropriate techniques. Preferably, the seam panels 12and 13 are joined by a predetermined pattern of heat/pressure orultrasonic welds which withstands the forces and stresses generated onthe pull-on diaper 20 during wear. The seams 32 also connect thecontinuous extensible waistbands 57 and 59 to form the continuousextensible waist feature 60 about the waist opening 36. When the sideelastic member 70 and the waist elastic member 80 extend into the seampanel 12 and 13, the seams 32 anchor the side elastic member 70 in thefront region 26 to the side elastic member 70 in the back region 28 andanchor the waist elastic member 80 in the front region 26 to the waistelastic member 80 in the back region 28. Examples of seams are disclosedin U.S. Pat. No. 5,569,234 issued to Buell, et al. on Oct. 29, 1996,U.S. Pat. No. 5,607,537 issued to Johnson et al. on Mar. 4, 1997, U.S.Pat. No. 5,662,638 issued to Johnson et al. on Sep. 2, 1997, and U.S.Pat. No. 5,685,874 issued to Buell et al. on Nov. 11, 1997. Preferableseams are disclosed in European Patent Application No. 96118654.1 titled“Thermal Joining of Webs” filed on Nov. 21, 1996 (Christoph J. Schmitz).

In a preferred embodiment, the outer side edge 46D and 48D isnon-parallel to the inner side edge 46C and 48C and is non parallel tothe longitudinal center line 100. The outer side edge 46D and 48Dprojects laterally outwardly proximate the lower end edge 46B and 48B.The extensible ear 46 and 48 has a lateral width L1 between the innerside edge 46C and 48C and the outer side edge 46D and 48D proximate thelower end edge 46B and 48B greater than a lateral width L2 between theinner side edge 46C and 48C and the outer side edge 46D and 48Dproximate the higher end edge 46A and 48A. Therefore, the availableelastomeric material quantity in the lateral direction of the extensibleear 46 and 48 is greater proximate the lower end edge 46B and 48B thanproximate the higher end edge 46A and 48A. The extensibility proximatethe lower end edge 46B and 48B is enhanced. In addition, because bothextensible ear 46 and extensible ear 48 have greater lateral width(i.e., available elastomeric material quantity) proximate the lower endedge 46B and 48B, lateral width (i.e., available elastomeric materialquantity) further becomes greater proximate the lower end edge 46B and48B by combining the extensible ear 46 and the extensible ear 48.Because of the configuration being greater width proximate the lower endedge 46B and 48B, the pull-on diaper has more elastomeric materialquantity available about the leg openings while the pull-on diapermaintains elastomeric material quantity about the waist opening.Therefore, the pull-on diaper does not give too high pressure to theskin causing the negative skin incidence about the leg openings whilemaintaining a sustained fit about the waist opening. In a configurationwhere the extensible ear 46 and the extensible ear 48 are joined, theseam 32 is non-parallel to the longitudinal center line 100 as shown inFIG. 13 such that the seam 32 projects laterally outwardly proximate thelower portion 32A of the seam 32. Further, as explained hereinabove, thewaist elastic member 80 is joined to the waistband panel 6 and 7 of thechassis 41 in a tensioned (prestrained) condition and allowed to returnto the substantially untensioned condition while the side elastic member70 is joined to the extensible ear 46 and 48 in an untensionedcondition. Therefore, the circumference of the pull-on diaper 20 aboutthe continuous extensible waist feature 60 further becomes smaller underan untensioned condition than the circumference of the pull-on diaper 20through a portion of the extensible ear 46 and 48. This configurationfurther improves a sustained fit about the waist opening while reducingthe skin incidence about the leg openings. Herein “circumferentialdirection” refers to a direction along the waist opening in an assembledconfiguration of the pull-on diaper. Herein “circumference” refers to alength of the pull-diaper along the circumferential direction.

The continuous belt zone 38 is formed by the front and back extensibleears 46 and 48, a part of the chassis 41, and the continuous extensiblewaist feature 60 as shown in FIG. 1. The continuous belt zone is thatportion or a belt-like zone of the pull-on diaper which is extensiblesuch that the circumference of the continuous belt zone is extended forapplication of the pull-on diaper 20. When the pull-on diaper 20 isapplied to the wearer, the pull-on diaper 20 must be extended to securewider waist opening and wider leg opening for ease of application of thepull-on diaper 20. The continuous belt zone 38 is that portion capableof being extended. The continuous belt zone 38 is, in an assembledconfiguration shown in FIG. 1, encompassed by the waist edge 151 and 155of the pull-on diaper 20, the leg edge 153 and 156, the lateral edge 159of the crotch region 30 in the front region 26 and the back region 28.The continuous belt zone 38 has the least height typically at the earpanels. In the embodiment shown in FIG. 1, the least height of thecontinuous belt zone 38 is measured along the seams 32. The continuousbelt zone 38 also has a continuous lowermost line 35 which is notinterrupted by the leg openings 34, but is the closest to the legopenings 34. The continuous belt zone 38 has two portions; a continuouswaist belt zone 37 in which the continuous extensible waist feature 60extends, and a continuous lower belt zone 39 in which the extensibleears 46 and 48 and a part of the chassis 41 extend. In a preferredembodiment, the continuous waist belt zone 37 conforms with thecontinuous extensible waist feature 60.

In one preferred embodiment where the pull-on diaper shown in FIG. 3becomes an assembled configuration as shown in FIG. 1, the initialcircumference of the continuous belt zone 38 along the waist edge 151and 155 may be from 200 mm to 500 mm in an untensioned condition,preferably from 250 mm to 400 mm. The circumference of the continuousbelt zone 38 along the waist edge 151 and 155 extends up to at least 650mm, preferably at least 700 mm, more preferably at least 750 mm(extended circumference). The circumference of the continuous belt zone38 along the line 35 may be from 300 mm to 550 mm, preferably from 350mm to 500 mm. The least height of the continuous belt zone 38 measuredalong the seams 32 may be from 50 mm to 150 mm, preferably from 80 mm to120 mm. The height of the continuous waist belt zone 37 (i.e.,continuous extensible waist feature 60) may be from 5 mm to 40 mm,preferably from 15 mm to 30 mm. The combined lateral length of theextensible ears 46 and 48 in one side of the pull-on diaper 20 along theline 35 is from 50 mm to 120 mm, preferably from 60 mm to 100 mm.

The pull-on diaper having a configuration shown in FIG. 3, when itbecomes an assembled configuration, lowers the pressure to the skin ofthe wearer locally especially about the leg openings 34 because theextensible ear 46 and 48 has greater lateral width (availableextensibility in the lateral direction) proximate the lower end edge 46Band 48B. If necessary, the side elastomeric material 124 may use amaterial having lower SCRF50% force to further lower the pressure aboutthe leg openings 34. However, lowering the SCRF50% force about the legopenings 34 may result in losing sustained fit for the whole pull-ondiaper. Therefore, raising the pressure about the waist opening 36 maybe necessary to achieve a sustained fit for the whole pull-on diaper.This may be achieved by prestraining only the waist elastomeric material200 before joining to the waistband panel 6 and 7. In addition, thewaist elastomeric material 200 may use a material having a higherSCRF50% force to further raise the pressure about the waist opening 36.These combinations of force distributions allow the pull-on diaper toachieve a sustained fit about the waist opening with less incidence ofred marking on the skin about the leg openings. Alternatively, thepull-on diaper having a configuration shown in FIG. 3, when it becomesan assembled configuration, may provide a sustained fit about the legopenings and less incidence of red marking on the skin about the waistopening. This can be achieved, for example, using a material havinglower SCRF50% force for the waist elastomeric material 200 to lower thepressure about the waist opening 36. The side elastomeric material 124may use a material having a lower SCRF50% force. Further, the sideelastomeric material 124 may be prestrained before joining to the earpanel 6 and 7.

FIG. 14 shows an alternative embodiment of the pull-on diaper 20. Asshown, the outer side edge 46D and 48D of the extensible ear 46 and 48may extend parallel to the longitudinal center line (not shown in FIG.14) and is parallel to the inner side edge 46C and 48C. In addition, theextensible ear 46 and 48 has generally the same length L3 of theelastomeric material in the lateral direction proximate the lower endedge 46B and 48B and proximate the higher end edge 46A and 48A such thatthe extensible ear 46 and 48 provides generally the same availableelastomeric material quantity in the lateral direction in the extensibleear 46 and 48.

In another preferred embodiment where the pull-on diaper shown in FIG.14 becomes an assembled configuration, the initial circumference of thecontinuous belt zone 38 along the waist end edge 151 and 155 may be from210 mm to 510 mm in an untensioned condition, preferably from 260 mm to410 mm. The circumference of the continuous belt zone 38 along the waistedge 151 and 155 extends up to at least 650 mm, preferably at least 700mm, more preferably at least 750 mm (extended circumference). Thecircumference of the continuous belt zone 38 along the line 35 may befrom 300 mm to 540 mm, preferably from 390 mm to 490 mm. The leastheight of the continuous belt zone 38 measured along the seams 32 may befrom 50 mm to 150 mm, preferably from 80 mm to 120 mm. The height of thecontinuous waist belt zone 37 (i.e., continuous extensible waist feature60) may be from 5 mm to 40 mm, preferably from 15 mm to 30 mm. Thecombined lateral length of the extensible ears 46 and 48 in one side ofthe pull-on diaper 20 along the line 35 is from 50 mm to 120 mm,preferably from 60 mm to 100 mm.

The pull-on diaper having a configuration shown in FIG. 14, when itbecomes an assembled configuration, may provide a sustained fit aboutthe waist opening and less incidence of red marking on the skin aboutthe leg openings. To achieve it, the side elastomeric material 124 mayuse a material having lower SCRF50% force. Coincidentally, the force ofthe waist elastomeric material 200 may be raised by using a materialhaving higher SCRF50% force. The waist elastomeric material 200 may alsobe prestrained before being joined to the waistband panel 6 and 7 forthat purpose. Conversely, the pull-on diaper having the configurationshown in FIG. 14, when it becomes an assembled configuration, mayprovide a sustained fit about the leg openings and less incidence of redmarking on the skin about the waist opening. It is achieved by using amaterial having lower SCRF50% force for the waist elastomeric material200. Coincidentally, the force of the side elastomeric material 124 maybe raised by using a material having higher SCRF50%. The sideelastomeric material 124 may also be prestrained before joined to theear panel 10 and 11 for that purpose.

FIG. 15 shows an alternative embodiment of the pull-on diaper 20. Asshown, the outer side edge 46D and 48D is non-parallel to the inner sideedge 46C and 48C and is non-parallel to the longitudinal center line(not shown in FIG. 15). The outer side edge 46D and 48D projectslaterally outwardly proximate the lower end edge 46B and 48B. Therefore,the extensible ear 46 and 48 has a lateral width L5 between the innerside edge 46C and 48C and the outer side edge 46D and 48D proximate thelower end edge 46B and 48B, and a lateral width L4 between the innerside edge 46C and 48C and the outer side edge 46D and 48D proximate thehigher end edge 46A and 48A. The lateral width L4 is greater than thelateral width L5, therefore, lateral width (available elastomericmaterial quantity in the lateral direction) of the extensible ear 46 and48 is greater proximate the higher end edge 46A and 48A than proximatethe lower end edge 46B and 48B. The extensibility proximate the higherend edge 46A and 48A is enhanced. In addition, because both extensibleear 46 and extensible ear 48 have greater lateral width (availableelastomeric material quantity) proximate the higher end edge 46A and48A, lateral width (available elastomeric material quantity) furtherbecomes greater proximate the higher end edge 46A and 48A by combiningthe extensible ear 46 and the extensible ear 48. In a configurationwhere the extensible ear 46 and the extensible ear 48 are joined, theseam 32 is non-parallel to the longitudinal center line 100 such thatthe seam 32 projects laterally outwardly proximate the higher portion32B of the seam 32 as shown in FIG. 16. In FIG. 16, because the waistelastomeric material 200 is prestrained before joining to the waistbandpanel 6 and 7, the circumference along the continuous extensible waistfeature 60 is a little contracted. If the waist elastomeric material 200is further prestrained, the circumference along the continuousextensible waist feature 60 becomes smaller than the circumference ofthe pull-on diaper 20 through a portion of the extensible ear 46 and 48as shown in FIG. 17. As a result, the shape of the pull-on diaper 20 inthe assembled configuration may become similar to the shape shown inFIGS. 1 and 13. However, because of the original configuration of theextensible ear 46 and 48 having greater lateral width proximate thehigher end edge 46A and 48A, the pull-on diaper 20 shown in FIG. 17still has greater elastomeric material quantity proximate the higher endedge 46A and 48A.

In another preferred embodiment where the pull-on diaper shown in FIG.15 becomes an assembled configuration, the initial circumference of thecontinuous belt zone 38 along the waist end edge 151 and 155 may be from220 mm to 520 mm in an untensioned condition, preferably from 270 mm to420 mm. The circumference of the continuous belt zone 38 along the waistend edge 151 and 155 extends up to at least 650 mm, preferably at least700 mm, more preferably at least 750 mm (extended circumference). Thecircumference of the continuous belt zone 38 along the line 35 may befrom 300 mm to 530 mm, preferably from 380 mm to 480 mm. The leastheight of the continuous belt zone 38 measured along the seams 32 may befrom 50 mm to 150 mm, preferably from 80 mm to 120 mm. The height of thecontinuous waist belt zone 37 (i.e., continuous extensible waist feature60) may be from 5 mm to 40 mm, preferably from 15 mm to 30 mm. Thecombined lateral length of the extensible ears 46 and 48 in one side ofthe pull-on diaper 20 along the line 35 is from 50 mm to 120 mm,preferably from 60 mm to 100 mm.

The pull-on diaper having the configuration shown in FIG. 15, when itbecomes an assembled configuration, lowers the pressure to the skin ofthe wearer locally especially about the waist opening 34 because theextensible ear 46 and 48 has greater lateral width (availableelastomeric material quantity in a lateral direction) proximate thehigher end edge 46A and 48A. If necessary, the waist elastomericmaterial 200 may use a material having lower SCRF50% force to furtherlower the pressure about the waist opening 36. However, lowering theSCRF50% force about the waist opening 36 may result in losing sustainedfit for the whole pull-on diaper. Therefore, raising the pressure aboutthe leg openings 34 may be necessary to achieve sustained fit for thewhole pull-on diaper. This may be achieved by prestraining only the sideelastomeric material 124 before joining to the ear panel 10 and 11. Inaddition, the side elastomeric material 124 may use a material having ahigher SCRF50% force to further raise the pressure about the legopenings 34. These combinations of force distributions allow the pull-ondiaper to achieve a sustained fit about the leg openings and lessincidence of red marking on the skin about the waist opening.Alternatively, the pull-on diaper having a configuration shown in FIG.15, when it becomes an assembled configuration, may provide a sustainedfit about the waist opening and less incidence of red marking on theskin about the leg openings. This can be achieved, for example, using amaterial having lower SCRF50% force for the side elastomeric material124 to lower the pressure about the leg openings 34. The waistelastomeric material 200 may use a material having a higher SCRF50%force. Further, the waist elastomeric material 200 may be prestrainedbefore joining to the waistband panel 6 and 7.

The continuous belt zone 38 contributes to dynamically create fit forcein the pull-on diaper 20 when positioned on the wearer, to maintain thepull-on diaper 20 on the wearer. Although higher fit force generated bythe continuous belt zone 38 is preferable for sustained fit for thepull-on diaper, the continuous belt zone 38 generating the higher fitforce causes difficulty in applying the pull-on diaper to the wearerbecause the applicator of the pull-on diaper must apply higher force tothe pull-on diaper to extend the continuous belt zone 38 such that thewider waist opening and wider leg openings are secured. Because thecontinuous belt zone 38 comprises the side elastomeric material 124 andthe waist elastomeric material 200, both elastomeric materials must beextended during the process of pulling on the pull-on diaper. Therefore,the property of extensibility of the continuous belt zone 38 includingthe side and waist elastomeric materials are more important than thoseof a solo continuous extensible waist feature 66 and/or those of a soloextensible ear 46 and 48, though the property of extensibility of a solocontinuous extensible waist feature 60 and/or a solo extensible ear 46and 48 are still important. Prior art such as U.S. Pat. No. 5,601,547published on Feb. 11, 1997 to Kato, et al. discloses a waist elasticsystem with improved modulus of elasticity for a child's training pantproviding a more comfortable fit and improved ease of use. However, thispublication is directed to only improvement of the waist elastic system.

The continuous belt zone 38 is extensible in the extension range from aninitial extension (i.e., 0%). The extension is calculated from theequation: ((extended circumference−initial circumference)/initialcircumference)×100 and expressed in the unit of % (percent). The initialcircumference of the continuous belt zone 38 is the circumference underan untensioned condition of the continuous belt zone 38. The extendedcircumference is the circumference under an extended condition of thecontinuous belt zone 38. The wider extension range allows to secure thewider waist opening and the wider leg openings for application of thepull-on diaper 20. The wider extended circumference allows to secure thewider space between the extended pull-on diaper and the body of thewearer for application of the pull-on diaper 20. The circumference ofthe continuous belt zone 38 is the circumference measured along thewaist border of the continuous belt zone 38 (i.e., the waist edges 151and 155 of the continuous extensible waist feature 60).

In order to provide a benefit of ease of application of the pull-ondiaper (i.e., wider waist opening and wider leg openings), the initialcircumference of the continuous belt zone 38 of the pull-on diaper maybe between about 220 mm and about 500 mm, and the extended circumferenceof the continuous belt zone 38 of the pull-on diaper is at least about650 mm. More specifically, the initial circumference of the continuousbelt zone 38 of the pull-on diaper designed to fit toddlers weighingfrom about 7 kgs to about 10 kgs is between about 220 mm and about 460mm, preferably about 250 mm and about 360 mm. The initial circumferenceof the continuous belt zone 38 of the pull-on diaper designed to fittoddlers weighing from about 9 kgs to about 14 kgs is between about 240mm and about 480 mm, preferably about 270 mm and about 380 mm. Theinitial circumference of the continuous belt zone 38 of the pull-ondiaper designed to fit toddlers weighing about 13 kgs or above isbetween about 260 mm and about 500 mm, preferably about 290 mm and about400 mm. The extended circumference of the continuous belt zone 38 of thepull-on diaper designed to fit toddlers weighing from about 7 kgs toabout 10 kgs is at least about 650 mm, preferably about 700 mm. Theextended circumference of the continuous belt zone 38 of the pull-ondiaper designed to fit toddlers weighing from about 9 kgs to about 14kgs is at least about 700 mm, preferably about 750 mm. The extendedcircumference of the continuous belt zone 38 of the pull-on diaperdesigned to fit toddlers weighing about 13 kgs or above is at leastabout 750 mm, preferably about 800 mm. The pull-on diaper has theextension range up to at least the extension of about 125%, preferablyabout 135%, more preferably about 150%.

The continuous belt zone 38 also has a force versus extension curve inthe extension range and a modulus of extensibility in the extensionrange. The force versus extension curve represents a relationship of aforce required to extend the continuous belt zone 38 and an extension ofthe continuous belt zone 38. The modulus of extensibility represents arate of force change to extension change and is expressed in the unit ofg/% extension (grams/percent extension). The method to obtain themodulus of extensibility is set forth below. The higher modulus ofextensibility means higher rate of force change to extend the continuousbelt zone 38. When modulus of extensibility becomes dramatically high,the applicator recognizes that part as a limitation of extension.Conversely, the lower modulus of extensibility means lower rate of forcechange to extend the continuous belt zone 38. This allows the applicatorto extend the continuous belt zone 38 without adding higher force, andthe applicator may not recognize the limitation of extension. Therefore,it is preferable the continuous belt zone 38 has lower modulus ofextensibility at the extended circumference for application of thepull-on diaper. In addition, the lower force to extend the pull-ondiaper up to the extended circumference for application of the pull-ondiaper is preferable.

In order to provide a benefit of ease of application of the pull-ondiaper (i.e., lower force to obtain the extension for application of thepull-on diaper and lower modulus of extensibility at the extension forapplication of the pull-on diaper), the modulus of extensibility at theextension of 125% is not greater than about 150 g/% extension,preferably not greater than about 120 g/% extension, more preferably notgreater than about 100 g/% extension. The modulus of extensibility inthe extension range up to the extension of 125% is preferably notgreater than about 150 g/% extension, more preferably not greater thanabout 120 g/% extension. The modulus of extensibility at the extensionof 135% is not greater than about 200 g/% extension, preferably notgreater than about 175 g/% extension, more preferably not greater thanabout 150 g/% extension. The modulus of extensibility in the extensionrange up to the extension of 135% is preferably not greater than about200 g/% extension, more preferably not greater than about 175 g/%extension. The modulus of extensibility at the extension of 150% ispreferably not greater than about 300 g/% extension, more preferably notgreater than about 250 g/% extension. The force to obtain the extensionof 125% is preferably not greater than about 5,000 g, more preferablynot greater than about 4,500 g. The force to obtain the extension of135% is preferably not greater than about 6,000 g, more preferably notgreater than about 5,500 g. The force to obtain the extension of 150% ispreferably not greater than about 9,000 g, more preferably not greaterthan about 8,000 g.

FIG. 18 shows one preferred example of the force versus extension curvesof the continuous belt zone 38 of the pull-on diaper. FIG. 19 shows themodulus of extensibility versus extension curve of the example shown inFIG. 18. The methods to obtain a force versus extension curve of thecontinuous belt zone 38 and a modulus of extensibility versus extensioncurve are set forth below.

The methods to obtain a force versus extension curve of the continuousbelt zone and a modulus of extensibility versus extension curve are setforth below. This method is a modified ultimate tensile test methodcontained within the “Sintech TestWorks” software package for measuringa force versus extension curve. This measurement is basically designedto simulate the applicator habit in putting a pull-on diaper on thewearer by using the Instron force tester and two horizontal bars in theplace of the jaws starting from 0 g force to 10,000 g force or when thediaper breaks, which represents the ultimate force applied to thecontinuous belt zone. The method gives “force versus extension” curvefrom the untensioned condition up to the ultimate tensile of the diaper.The force versus extension data generated as described above can then beconverted to “modulus of extensibility versus extension”.

This test method requires sample preparation as described below.

-   (1) The sample diaper to be tested should be taken from the bag-   (2) Measure the diaper inside circumference at the waist edge of the    diaper using measuring tape without stretching diaper during the    measurement (Untensioned Diaper Circumference)

This test method involves the following equipment below.

(1) Tensile/Cycle Tester Instron Model 5564 (2) Operation SoftwareSintech TestWorks version 3.0 (3) Loadcell Instron Static Loadcell 100N(4) Jaw 20 mm diameter × 150 mm length Teflon coated bar mountedhorzontally to upper and lower jaws

This test method is performed with the setting below.

-   (1) Test Method: Tensile-   (2) Travel Speed: 20 inch/minute-   (3) Gauge Length: distance of the center of the upper bar and the    lower bar is calculated as below    (Gauge Length)=(Untensioned Diaper Circumference)/2−30 mm-   (4) # of Cycle: 1 cycle-   (5) Break Sensitivity: 75%-   (6) Load Limit: 10,000 g-   (7) Calculation Input: Untensioned Diaper Circumference, Load Point    at 500 g, 1,000 g, 2,000 g, 3,000 g, 4,000 g, 5,000 g, 6,000 g-   (8) Calculation Results: Diaper Circumference at 0 g (=untensioned),    extension at load point at 500 g, at 1,000 g, at 2,000 g, at 3,000    g, at 4,000 g, at 5,000 g, at 6,000 g, at Peakload, Load at Peak,    circumference at peak load    -   Diaper circumference at certain load point is calculated as        below        (Diaper Circumference)=(Untensioned Diaper        Circumference)+(extension)×2    -   Extension at certain load point is calculated as below.        (Extension)=(Extended Diaper Circumference−Untensioned Diaper        Circumference)/(Untensioned Diaper Circumference)

The test method is executed as below.

-   (1) Prepare sample diapers and measurement data-   (2) Set up the Instron Loadcell and Jog following the Instron    Setting above then calibrate the Loadcell-   (3) Log in to the TestWorks system-   (4) Choose tensile test method from the method list tool bar, then    let Control Panel, Load Meter, Extension Meter, and Handset show up    on the screen-   (5) Enter the Untensioned Diaper Circumference data into gauge    length in the calculation input-   (6) Set up the Gauge Length using a ruler following the Gauge Length    Setting described above    -   (Example: Untensioned Diaper Circumference=380 mm→Gauge        Length=380/2−30=160 mm)-   (7) Reset the Load in the Load Meter and Extension in the Extension    Meter-   (8) Measure the product weight by putting a product to be test on    the upper bar then reset the load again-   (9) Put the sample diaper on the Jog with checking the cuff/leg    elastic does not stick on the bar-   (10) After putting the diaper on the jog, do not reset the Load    Meter-   (11) Click the “Run” to start the measurement-   (12) When the measurement has been done, the jog returns to the    original position-   (13) Click “File” to save the data and remove the diaper-   (14) Repeat the step 6-13 for other sample

The data is evaluated as below.

-   (1) After completion for all samples, export the data into an    appropriate spreadsheet program (i.e. Microsoft Excel)-   (2) “Force versus extension curve” is obtained by plotting the force    in grams against diaper extension in percent-   (3) “Modulus of extensibility” is obtained by dividing the force    difference between two successive data points by the extension    difference between the two same points-   (4) “Modulus of extensibility versus extension curve” is obtained by    plotting the modulus of extensibility obtained in the step of (3)    against diaper extension in percent

As stated above, the continuous belt zone 38 creates fit force in thepull-on diaper 20 when positioned on the wearer, to maintain the pull-ondiaper 20 on the wearer. The continuous belt zone 38 further includes azone of extensibility which comprises elastic materials such as the sideelastomeric material 124 and the waist elastomeric material 200. Thezone of extensibility may further include a leg elastomeric material.The leg elastomeric material comprises elastomeric material such as theelastic strands 64 as shown in FIG. 3. The leg elastomeric material maycomprise the material used for the side elastomeric material 124 or thewaist elastomeric material 200. Herein “zone of extensibility” refers toa continuous area or a continuous zone of the pull-on diaper renderedextensible by an elastomeric material having the form of a continuousplane layer with or without apertures, or the form of strands which arenot connected to each other. The zone of extensibility is that portionin the continuous belt zone 38 which substantially generates the skincontact pressure in the continuous belt zone 38. The skin contactpressure generated by the zone of extensibility contributes tomaintaining the pull-on diaper on the wearer (sustained fit of thepull-on diaper). The skin contact pressure in the zone of extensibilitymay not be uniform everywhere. For example, the skin contact pressure ofthe zone of extensibility between about the waist opening and about theleg openings may be different from each other. Additionally, the skincontact pressure may vary around the radial circumference of the diaperor the leg circumference of the diaper.

In the zone of extensibility, the elastic component of the elastomericmaterial (such as a plurality of first strands 125 and a plurality ofsecond strands 127 of the elastomeric scrim 124 shown in FIG. 8)pressing on the skin usually generates higher skin contact pressure thanthe remainder of the area of the zone of extensibility (such as aplurality of apertures 132 of the elastomeric scrim shown in FIG. 8).Therefore, lower skin contact pressure of the elastomeric materialpressing on the skin leads to a reduction of the local skin incidence.

The skin contact pressure of the elastomeric material (side elastomericmaterial and/or waist elastomeric material) pressing on the skin shouldbe not less than about 0.1 psi to maintain the pull-on diaper 20 on thewearer, preferably not less than about 0.2 psi, more preferably not lessthan about 0.3 psi. The skin contact pressure of the elastomericmaterial (side elastomeric material and/or waist elastomeric material)pressing on the skin should be not greater than about 0.75 psi not tocause the skin incidence in the zone of extensibility, preferably notgreater than about 0.65 psi, more preferably not greater than about 0.55psi. Any combination selected from the above range of the skin contactpressure of the elastomeric material pressing on the skin is effectivein providing a pull-on diaper with a reduced risk of drooping, saggingor sliding down from the position on the wearer, with a reduced risk ofskin incidence in the zone of extensibility, and with a reduced risk ofskin incidence by the elastomeric material. The skin contact pressure ofthe elastomeric material (leg elastomeric material) pressing on the skinshould be not less than about 0.1 psi to maintain the pull-on diaper 20on the wearer, preferably not less than about 0.2 psi, more preferablynot less than about 0.3 psi. The skin contact pressure of theelastomeric material (leg elastomeric material) pressing on the skinshould be not greater than about 0.75 psi not to cause the skinincidence in the zone of extensibility, preferably not greater thanabout 0.65 psi, more preferably not greater than about 0.55 psi. Themethod to obtain the skin contact pressure of the elastomeric materialpressing on the skin is set forth below.

The skin contact pressure of the elastomeric material pressing on theskin within the zone of extensibility about the waist opening may behigher than the skin contact pressure of the elastomeric materialpressing on the skin at the remainder of the area within the zone of theextensibility to provide a sustained fit of the pull-on diaper about thewaist opening. The skin contact pressure of the elastomeric materialpressing on the skin within the zone of extensibility about the legopenings may be higher than the skin contact pressure of the elastomericmaterial pressing on the skin at the remainder of the area of the zoneof the extensibility to provide a sustained fit of the pull-on diaperabout the leg openings. The skin contact pressure of the elastomericmaterial pressing on the skin about the waist opening and about the legopenings within the zone of extensibility may be higher than the skincontact pressure of the elastomeric material pressing on the skin at theremainder of the area within the zone of the extensibility. Thedifference between the highest skin contact pressure of the elastomericmaterial pressing on the skin within the zone of extensibility and thelowest skin contact pressure of the elastomeric material pressing on theskin should be less than about 0.65 psi, preferably less than about 0.45psi, more preferably less than about 0.25 psi. As the difference becomescloser to zero, the skin contact pressure of the elastomeric materialpressing on the skin within the zone of extensibility becomes closer touniform everywhere. This further contributes to reduce a skin incidencewhich have caused by the different pressure.

The pull-on diaper 20 further comprises additional elastomeric materialsuch as the spacing means 58 of the inner barrier cuff 54. It ispreferable that these additional elastomeric material incorporated inthe pull-on diaper 20 gives skin contact pressure of the additionalelastomeric material pressing on the skin of the wearer of not greaterthan about 0.75 psi. Preferably, the skin contact pressure of theadditional elastomeric material pressing on the skin of the wearer isnot greater than about 0.65 psi, more preferably not greater than about0.55 psi.

The method to measure the skin contact pressure of the elastomericmaterial pressing on the skin within the zone of extensibility is setforth below. The method entitled “AMI Air-pack Type Contact SurfacePressure Measurement System” is commercially supplied by AMI Co., Ltd tomeasure the surface contacting pressure generated between softmaterials. This method is modified to measure the contacting pressurebetween the diaper and wearer's body. Air pressure indicated representsthe force of contact surface from which the force absorbed by ductilityof the material has been deducted. The sensing part is composed of anair pack made of a very soft thin film, of a tube introducing to themain unit and the measured value is converted into DC output (10 mV=1gf/cm²).

This test method requires sample preparation below.

-   (1) The sample diaper to be tested should be taken from the bag-   (2) Measure the width of the actual elastomeric component of the    elastomeric material (i.e. elastic strands) under the 50% stretched    condition and calculate the percent area of the elastomeric    component

This test method entitled “AMI Air-pack Type Contact Surface PressureMeasurement System” involves the following equipment below.

(1) Air-pack AMI Co., Ltd Model ∅15 mm (2) Main Unit AMI Co., Ltd AMI3037-2 (3) Option Unit AMI Co., Ltd AMI 3037-2B (4) Air Cylinder AMICo., Ltd (5) Calibration Set AMI Co., Ltd (6) Data Collector ANRITSUMETER Co., Ltd. AM-7052 (7) Data Converting Software ANRITSU METER Co.,Ltd. DATA COLLECTOR System AMS7006WIN ver. 2.0 for Windows

This test equipment described above requires the setting below.

-   (1) Connect the output cable to the output connector of the main    unit and connect the opposite side of the output cable to the data    collector-   (2) Turn on the power-   (3) Use the gear, push the head of air cylinder to the end in the    shortest length-   (4) Connect the air pack to the air cylinder-   (5) Insert the pin into the blue head on the gear, turn the gear    until the pin comes to the end, wait 3 seconds-   (6) Press the release lever for making air cylinder pressure to be    the same with and ambient pressure, wait 3 seconds-   (7) Insert the pin into the hole of the gear whose color is the same    with the air pack, turn the gear until the pin comes to the end-   (8) Remove the air pack from the air cylinder, turn the gear until    the pin comes to the end-   (9) Check if the output signal from the main unit is close to zero    with allowance of 5 mV (0.5 gf/cm²)-   (10) Connect the air pack to the main unit (connection should be    made in one action. If you renew connection, inside volume of air    pack must be change)-   (11) Press the air pack by hand flat or finger for removing all the    air from the air pack, check the output signal transmitted from the    main unit, be careful that this is the maximum measurement value and    that the system can't measure any values exceeding the maximum the    maximum measurement value. If the contact surface is bent too much,    and if output signal from the main unit exceeds +20 mV (2 gf/cm²),    connect the air cylinder and press the release lever-   (12) Prepare at least 2 air-packs for standard measurement

This method requires a standard mannequin as below.

The standard mannequin 350 shown in FIGS. 20 and 21 is modeled after thebody shape in a sitting posture of the wearer. The shape and thedimension of the standard mannequin 350 should be based on the bodydimension data taken from the actual diaper users. The standardmannequin 350 has an upper portion 352 and a lower portion 354. Theupper portion 352 and the lower portion 354 are divided by the lowertorso line 380. The lower torso line 380 is the circumferential linethrough the upper portion of the pubic bone. The upper portion 352includes a torso portion 353. The torso portion 353 has an upper surface355 (shown in FIG. 22) surrounded by the waist line 357 which is thecircumference line about the top waist of the torso portion 353. Thetorso portion 353 has a height defined by the height between the waistline 357 and the lower torso line 380. The circumference of the torsoportion 353 gradually increases from the waist line 357 toward the lowertorso line 380. The lower portion 354 includes a hip portion 356 at theback of the lower portion 354, and the leg portions 358 protruding fromthe hip portion 356 at the front of the lower portion 354. The hipportion 356 and the leg portions 358 are divided by the crotch creaseline 359 along the fat fold at the front of the body. The two legportions 358 have a crotch angle 362 which is the angle subtendedbetween the inner thighs 364. The leg portion 358 has a thigh line 366which is the circumferential line about the thigh of the leg portion358. The upper surface 355 has a shape surrounded by the waist line 357which comprises straight lines and curve lines. FIG. 22 shows onepreferred example of the shape of the upper surface 355 which isdetermined based on the actual wearer dimension. The standard mannequinis made of vinyl chloride.

The actual dimension of the standard mannequin for a diaper designed tofit the wearer weighing from about 7.0 kgs to about 10.0 kgs is shownbelow.

Circumference at the waist line: 460 mm Circumference at the lower torsoline: 470 mm Circumference at the crotch crease line: 310 mmCircumference at the thigh line: 275 mm Height of the torso: 75 mmCrotch angle: about 60 degrees

The actual dimension of the standard mannequin for a diaper designed tofit the wearer weighing from about 9.0 kgs to about 14.0 kgs is shownbelow.

Circumference at the waist line: 495 mm Circumference at the lower torsoline: 505 mm Circumference at the crotch crease line: 330 mmCircumference at the thigh line: 290 mm Height of the torso: 80 mmCrotch angle: about 60 degrees

The actual dimension of the standard mannequin for a diaper designed tofit the wearer weighing from about 13.0 kgs or above is shown below.

Circumference at the waist line: 520 mm Circumference at the lower torsoline: 530 mm Circumference at the crotch crease line: 350 mmCircumference at the thigh line: 305 mm Height of the torso: 85 mmCrotch angle: about 60 degrees

The measurement points for the waist elastomeric material and the sideelastomeric material are determined as below.

Point P1 is the point of the minimum radius of the waist curvature lineat the right side of the torso portion. Point P2 is the point of theminimum radius of the waist curvature line at the left side of the torsoportion. Point P3 is the point at the center of the back of the torsoportion. Point P4 is the point at the center of the front of the torsoportion. The for the measurement point P1, P2, P3, and P4 should bemounted about 10 mm below the waist line and should be fully covered bythe waist material of the sample diaper. Point P5 is the point at thefront of the right leg portion and point P6 is the point at the front ofthe left leg portion. The Air-packs for the measurement point P5 and P6should be mounted right under the elastomeric material contacting themannequin's leg portion.

The measurement points for the leg elastomeric material are the pointswhere the elastomeric material presses on the skin of the standardmannequin.

This method is executed as below.

-   (1) Set up the pressure measurement system following the setting    above-   (2) Prepare sample diapers and mount the diaper on the standard    mannequin-   (3) Place two Air-packs at the point P1 and P2 and measure the    pressure-   (4) Record the pressure measurement data and check if the pressure    signal recovers close to zero with allowance of 5 mV (0.5 gf/cm²)-   (5) Place two Air-packs at the point P3 and P4 and measure the    pressure-   (6) Record the pressure measurement data and check if the pressure    signal recovers close to zero with allowance of 5 mV (0.5 gf/cm²)-   (7) Place two Air-packs at the point P5 and P6 and measure the    pressure-   (8) Record the pressure measurement data and check if the pressure    signal recovers close to zero with allowance of 5 mV (0.5 gf/cm²)-   (9) Repeat the step 2 to 8 for 1 sample diaper

The data is evaluated as below.

-   (1) “Local average skin contact pressure within the zone of    extensibility” is obtained by convert the measured voltage into psi    (10 mV=1 gm/cm²)-   (2) “Skin contact pressure of the elastomeric material pressing on    the skin” is then obtained in psi by dividing the “local average    skin contact pressure within the zone of extensibility” obtained    above by the percent area of the elastomeric component

It is understood that the examples and embodiments described herein arefor illustrative purpose only and that various modifications or changeswill be suggested to one skilled in the art without depending from thescope of the present invention.

1. A disposable garment having a front region, a back region, a crotchregion between the front region and the back region, the disposablegarment comprising: a chassis having a topsheet, a backsheet joined withthe topsheet, and an absorbent core interposed between the topsheet andthe backsheet, the chassis having a central panel having a waist edgeand side edges, an ear panel having a waist edge and a leg opening edge,wherein said ear panel waist edge has a first lateral width, and saidear panel leg opening edge has a second lateral width, said secondlateral width greater than said first lateral width, said chassisfurther having a waistband panel in the front region and the backregion, wherein the ear panel extends laterally outwardly from each sideedge of the central panel, and the waistband panel extendslongitudinally outwardly from the waist edge of the central panel andthe waist edge of the ear panel, a waist elastomeric material joined toand extending continuously along the waistband panels in the frontregion and the back region so as to form a continuous extensiblewaistband in the front region and the back region, a side elastomericmaterial joined to the ear panel so as to form extensible ears, whereinsaid side elastomeric material is disposed over substantially all ofsaid ear panel to provide extensibility extending from said leg openingedge to said waist edge, and wherein the side elastomeric material andthe waist elastomeric material are separate elements and are disposed soas not to overlap to each other, and seams joining said ear panel to acorresponding portion in the opposite front or back region so as to formtwo leg openings and a waist opening such that the extensible waistbandsform a continuous extensible waist feature.
 2. The disposable garment ofclaim 1 wherein the extensible ear is formed from a “zero strain”stretch laminate.
 3. The disposable garment of claim 1 wherein the waistelastomeric materials comprise two separate elements, one of which isjoined to the waistband panel in the front region, the other of which isjoined to the waistband panel in the back region, wherein the twoelements are connected to each other at the seams.
 4. The disposablegarment of claim 1 wherein the backsheet comprises an inner barrier filmand a nonwoven outer cover, and wherein the nonwoven outer cover issuperposed outside the inner barrier film.
 5. The disposable garment ofclaim 4 wherein the extensible waistband comprises an extended portionof the outer cover and the waist elastomeric material.
 6. The disposablegarment of claim 4 wherein the extensible ear comprises an extendedportion of the outer cover and the side elastomeric material.
 7. Thedisposable garment of claim 1 wherein the waist elastomeric material issuperposed inside an innermost surface of the garment.